Let's review:
Stator output yellow and chassis ground to the rectifier input.
Rectifier output to the headlight socket.
One wire to the filament terminal, other wire to the bulb shell terminal.
So far so good.
The fly in the ointment might be the stock GG voltage regulator. Let's say the GG stator can put out 60 volts AC when the revs go up. The GG regulator is supposed to clip this at ~13VAC so your bulbs don't burn out.
There have been many postings about stock regulators not performing properly. I would guess your new rectifier is converting to DC OK, but an AC overvoltage would give you a DC overvoltage and burn out the bulbs.
The only solution is to use a regulator/rectifier unit instead of the basic rectifier shown in your picture. It would then protect against overvoltage. You could try adding a zener diode that would block voltage instead but they aren't cheap.
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2011 EC250E
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