ACK to all earlier postings: won't worry about the "under side cover" installation location. kanuck69: already ordered a "super kit" from RoadsterCycle, otherwise, I would have been happy to take your MOSFET off your hands -- sincere thanks for the offer. As an aside on the "hot spot on the passenger's leg" comment... What passenger? :-).
Update on post-headlight-relay-bypass status... I rode the bike into work this morning. Got a steady 14.1-14.3V across the battery within a few seconds of pulling away from a stop, and at all other times while moving. EXCEPT (and here's where it gets interesting), the turn signals appear to drop the voltage across the battery by approximately 0.4V, and the brake lights drop it by 0.9-1.0V. At idle (stopped at intersections), this makes for an uncomfortably low voltage reading, occasionally dipping below 12.0V. Is this normal?
On a conventional (stock) R/R, how is the brown "load sensing" wire supposed to work? Any way to test that functionality? Obviously, this will be OBE when the MOSFET R/R gets installed, but inquiring minds want to know :-).
On the matter of the "blue wire bypass", in theory, this should make for an easier MOSFET R/R installation because I won't have to worry about splicing in the yellow relay "engine is running" wire into one of the stator leads, yes? Beyond that, even if the relay load is negligible, it isn't zero, so completely disabling it should help.