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I finally finished some of the mods I had been working on on the 550. Most notable is the fuse box and headlight cut relay that kills the headlight during start up. The new setup added 3 fuse slots, upgraded to blade type (ATC/ATO) fuses, and allowed me to properly power my heated grips, and accessory power socket. In the conversion I also used slightly larger wire for better conductivity. You can compare the two systems below.

Old fuse boxes (accessory fuse [top, open] & main [bottom, white label])

New fuse box (left) and start-up headlight cut relay (right)

When I tested everything, I also checked how well the ZX10 regulator is working. Seems to be just fine and happy in my little 550. I have yet to test ride it, but with the new tires, and rebuilt forks/new fork seals, I think I'll have a nice reliable bike again for this riding season.