Charging System Not Working? Please Help!

I had a similar reaction, but his photos of a melted headlight bulb are impressive! Actually, though, I would have expected the bike to just stall. Without a battery or capacitor, the voltage fluctuates a lot and doesn't let the ignition coils to charge properly. With a 3 phase alternator, though, maybe it would work. The regulator will be working hard to control the voltage though.

Here's the long thread:
kzrider.com/forum/viewthread.php?tid=23240

On an early Z you should not get more than 16 volts going to the battery. If you are, you have a regulator or rectifier problem. Most likely a regulator. Kawasaki had a problem with the manufaturing of the regulators in the 70's. The stuff (can't remember the name) like epoxy which should be a little soft gets hard after 25 years and then it shrinks and pulls the connections/components off the circuit board. I had the same problem and when testing all my spare regulators (that came off working bikes in the 70's) all of them were bad!! Get an eletronic regulator/rectifier, install and forget about it. TFH