Hi Kevin,
First of all, it sounds as if you have the wiring correct, but just check it again. Assuming you have the Miller wiring diagram for reference - the only difference to change to 12 volt is the wiring between the alternator, rectifier and the main switch. Your wiring should be - Alternator brown to rectifier 1 (as original), disconnect red (rectifier3 to switch3), connect both alt green and yellow to rect3 (all generator output will now go through blue wire to switch6 - making terminals 2, 3 and 4 obsolete). Connect the zenor diode into blue lead. Your bike should now be wired for 12 volt and you should get a charge going to the battery when the engine is running.
The lack of lights is probably down to a second problem (poor contact in the main switch - probably terminal 6). I'll get back to you later with details of how to rectify it (I need to refresh my memory!!).
Right - memory refreshed!
If you have got a poor contact, you will need to dismantle the switch in order to tweek the contacts. As I said, it is probably contact 6 - this is a double decker contact (and the lower part is the one that feeds the lights!).
Start by pushing out the roll pin that secures the knob, then lift the switch out of the nascelle. On the underside you will find 2 brass nuts (one holds contact 9), undo them and lift the top plate and bezel from the switch. Now, depending on whether you have an early or late switch, you will find there is a steel washer and either a split pin or spring clip retaining the centre drum. Carefully remove the clip or split pin - under the washer there are 2 springs and balls. You will now be able to press the centre drum out of the switch and gain access to the contacts. Carefully tweek each contact to increase it's pressure on the drum. Clean the drum and lubricate it with a smear of Vaseline and push it back into the switch body (you may need a small screwdriver to ease the contacts back as you insert the drum). Push the drum fully home and make sure it has located on the stop on the underside of the switch body. Add a little more Vaseline to the holes before replacing the balls and springs. The rest of the re-assembly is just the reverse of the dismantling.
Good luck!
Regards,
Eddie.
P.S. Dont worry if contacts 1, 5 & 6 look a bit twisted - they are like that from new!
