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Discussion Starter · #1 ·
I have a 1985 Kawasaki zn 1100 ltd. I have installed a new stator and regulator. If i press the button on the dash it tells me that the bike is charging at around 13.5 volts. But when i check with a voltage tester at the battery I'm not getting the voltage. The voltage slowly rises when at a idle, but drops when i rev it up. If I unhook the battery when going the bike cuts out. If anyone has a idea which i can try it would be greatly appreciated. Thanks
 

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The first thing is to not disconnect the battery when the engine is running. That can blow the ignition module and get a bit expensive as the battery is a critical component in regulating voltage.

If the battery is not charging at the battery, yet the bike's voltmeter reads 13.5 VDC at a fast idle, I would suspect the battery is either sulphated or one or more cables are corroded at one or both ends.

If you take your service manual and walk through the charging system diagnostics they will lead you right to the problem.
 

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Discussion Starter · #3 ·
I don't have a service manual, its a new battery, used it for my skidoo all winter with out a hitch, had the battery tested and it good. Good connections at the battery, Gnd goes to the frame. Haven't tore into the pos yet, didn't want to unwrap all of the wiring unless i had to. The bikes voltmeter is reading 13.5 vdc at idle, it does not change regardless of the revs. The bike had sat in a shed for about 8 years, and was not charging right when it was used last. Runs like a top now except this issue. Thanks
 

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This covers the older Kawasaki's but might apply to yours:

Alternator Testing For the Older 4’s(Z1’s,Kz 900’s, Kz1000’s,Kz1100’s and GPz1100’s).

To check to see if the alternator is working you need to follow these simple steps:

1. Fully charge the battery as this will be the power source during this test.

2. Disconnect the Regulator/Rectifier at the plug that has the six wires in it.

3. Start the engine and let it warm to operating temperature.

4. If you're worried about overheating, position a large fan for cooling the engine.

5. After the engine has reached operating temperature, have a helper assist you, and using a multi-meter, read the output at the three yellow wires (or the alternator output wires)at the disconnected connector.

6. Raise the engine speed to 4000 rpm, and see what the three YELLOW wire combinations(or any alternator output wires) are(1-3,2-3 & 1-2). The output will be around 50 Volts A.C.(Alternating Current). BE CAREFUL, AS THERE IS A SHOCK HAZARD HERE!!

7. If any of the combinations are low or non-existent, the stator(wire windings) are bad and must be replaced.
Some of the older Z1’s and KZ900’s were phase sensitive, so check the wire colors carefully.

8. Using an OHMETER, Check the three wire combinations again, looking for a reading of 0.36 - 0.54 OHMS. If the readings are above or below, the stator may be bad and need replacement

9. Before ordering a new stator, check the connections from the stator as there are electrical "Bullet" connectors that may be damaged or dirty.
Inspect the wiring for signs of shorting or overheating too. Z1 Enterprises, Inc. - Specializing in Vintage Japanese Motorcycle Parts sells replacement rubber grommets for the alternator output wiring, they get hard and could leak oil after a while.

10. Check the wiring coming out of the grommet as there have been situations where the wires were damaged causing a short(I.E. twisted together with insulation damage).

11. The sprocket cover may have to be removed to access the electrical connectors coming from the alternator and possibly the left foot peg, and shifting lever will have to come off.

_________________________________________________________________

If your bike has the smaller automotive style of alternator, then more experianced mechanics should be able to help you.
 

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Discussion Starter · #6 ·
Thanks for the info, i will have to try this again. I have already installed a new stator and rectifier from rmstator. The previous owner said that he had been told it had a faulty stator. Thus i purchased a new one, but it did not seem to fix my problem. I'm thinking during the week im going to strip down the wiring to search for a bad connection.
 

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Alternator Stator Replacement On the Older 4’s
Source for replacement Stators
A. ElectroSport Industries - Motorcycle, Dirt Bike and ATV Aftermarket Electrical Parts (They have a trouble shooting page)
B. Custom Rewind -- High Quility Remanufactured Motorsports Electronics, Rotors, Stators, Ignition Systems
C. www.rmstator.com
D. www.ricksmotorsportselectrics.com [5]
E. www.regulatorrectifier.com

1. If by testing either by checking the output voltage from the stator or by using and ohmmeter for resistance and the stator is determined to be bad, replacing the stator is not a difficult job.

2. The motorcycle owner should have on hand a replacement alternator gasket as it will tear on removal and leak if reused.

3. Put the bike on the center stand if possible and lean it to the right to minimize the oil volume that could come out when the alternator cover is removed.

4. Have selection of Metric wrenches and sockets along with Metric Allen keys to be able to accomplish this repair. ¼” and 3/8” ratchets and extensions may be needed along with Allen bits.

5. Remove the gear shift lever, the sprocket cover and possibly the left foot peg assembly.

6. A catch pan for what little oil will be lost should be positioned under the alternator on the left side. Newspapers will soak up any oil lost or some kitty litter will do as an absorbent.

7. Remove the alternator cover fasteners, some bikes use a socket head cap screw(Allen type) and others use the Phillips head type, the #3 screwdriver bit fits best for those. Use a small dish or can to collect the removed fasteners from the parts to prevent loss/damage.

8. The alternator stator is secured to the inside of the cover usually with three Allen headed bolts, Some bikes may have Torx style fasteners, Remove them and disconnect the three yellow wires that have bullet connectors on them from the bundled wires inside the sprocket cover.



9. If your bike has some color other than yellow for the alternator output wires, make note of what goes where as the older Kawasaki’s were phase sensitive in regard to the regulator/rectifiers.

10. When installing the replacement stator, clock or position the output wires and grommet so they fit into the small port under the alternator cover without being pinched or damaged.

11. Tighten the three Allen or Torx fasteners, securing the replacement stator to the cover. I like using the BLUE Loctite # 242 for hardware that can be removed with hand tools.

12. Remove the old gasket from the mating surfaces of the alternator cover and engine case by scraping with a piece of sharpened plastic like Lexan or Plexiglass as these will not gouge the soft Aluminum
Cases. Avoid using a metal gasket scraper for this.

13. Position the alternator cover, checking for pinched wiring and install the fasteners with a little silver anti-seize on the threads, tightening to the correct torque.

14. Connect up the output wires to the mating female bullet connectors and while you’re in there, check the routing of the wire bundle that runs through there.

15. Inspect for signs of heat damage to the wire insulation and vibration damage too.

16. The side stand switch, neutral switch, and oil pressure switch wiring are all bundled with the alternator output wiring running above and behind the engine output sprocket. This bundle runs in a channel as it goes up toward the various electrical connections.

17. The regulator/rectifier plug on the 80’s bikes usually has six wires in it:

A. One WHITE with RED stripe, this is the bikes main power wire usually 12 gauge in size.

B. One smaller Brown wire, probably 18 gauge or so, the voltage sense wire for the regulator/rectifier, helps keeping it from overcharging the battery.

C. One BLACK with YELLOW stripe wire, part of the ground circuits, maybe 16 gauge in size.

D. Three YELLOW wires, the alternator output wires going to the regulator/rectifier which converts the Alternating Current(A.C.) to Direct Current(D.C.) using rectification, producing the power to run the motorcycle and charge the battery.

18. Reinstall the sprocket cover, again checking for pinched wires before tightening. Install the shifter on it’s splined shaft checking for proper location, and the left side foot peg assembly.

19. Except for the minor oil spill and reluctant fasteners, it’s not a very difficult job to do.
 

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Discussion Starter · #8 ·
Finally got to check and with the stator disconnected I'm getting around 20v and when i rev up it gos to about 51. But with the stator connected I'm getting 11v and when revved up it drops. Any idea, I'm just checking this first before i haul the tank off to check at the regulator. Also the bike revs up with the stator disconnected and idles back down once reconnected. Thanks
 
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