There's a couple of little mods I do to every bike I own and I'm having a bit of trouble with the Versys.
I rewire the battery cables, this consists of:
Battery + - Starter Relay
Starter Relay - Stator Motor
Battery - - Engine Ground
I also rewire the charging system, replace the regulator rectifier to a series reg rec and wire the outputs of this directly to the battery terminals via a fuse.
I do this to increase the performance of these components. I use thicker gauge cable which tends to offer less voltage drop and makes the system a bit more reliable!
The issue I'm having with the Versys...
The headlight relay is triggered from one of the phases from the stator. I've disconnected the stator plug to feed directly to my new Reg Rec, but when I connect a 12v supply to the existing stator wiring, the starter relay trips and the starter motor spins.
Examining the wiring diagram, this makes sense, however obviously this isn't the case with the stock wiring.
So my question... What have I missed?! I've traced and traced wiring in the diagram and can't out my finger on where I've gone wrong. Have I got a failed relay box? I've tested this on a bench and it passes as per the manual.
Any thoughts on the issue anyway? For now I've run some headlight wiring direct to an Aux fuse box I've fitted under the seat so the bike is rideable, but I would like to utilise the headlight relay circuit if possible!
Thanks so much in advance!