Spotting KZ...

So the ol gal is leaking oil, not really sure from where except from the left side of the bike. My question is should I just enjoy my summer, ride and keep an eye on the oil level? Or just take the hit and tear the covers off the left side to figure out where its coming from? So having said that, is it as easy as removing the alternator cover and the big cover behind it? Or are there some parts back there that will move or bind when i try to put it back together or whatever. I can say its not coming from the bottom of the engine, but rather on the left side from one of the covers. Thanks!

Would first check this grommet.

Click > Grommet

Could also be gunge from the counter-shaft sprocket.

Good Fortune!

My bike is leaking also. I thought it was the base gasket so I ordered some new "O" rings from rob @ z1enterprises.

Also a clutch cover gasket. I thought I had a stator cover gasket but I don't .

After looking closer I determined the oil is comming out of the stator.

I'm going to ride for now and fix when the weather is too stinkin hot to ride since I might install a newer head and jugs. Roy

I bought this grommet a few weeks ago, haven't installed it yet mainly b/c my dad keeps telling me if i take the cover off I'll never be able to put it back on without help, sometihng about a magnet on the stator or something. So I figured I'd jsut ride, but the little drip drop of oil has turned into a small puddle about 4 inches in diameter. Is it just oil building up in the cover then finally pushing its way thru where the grommet(one you recommended) is supposed to be?

Yeah, sounds like a plan. I've been waiting 14 long months overseas to ride this dang thing and its being a pain to keep on the road lol.

The alternator wires are a common leak area. It appears to be because the stator is a "wet" stator meaning that it is in the oil. The wires coming from the stator collect the oil and it drips slowly down the wires out through the grommet.

I have this leak also and will redo it again soon. I have seen some guys put a bunch of adhesive on the wires inside the cover (don't remember what kind, something heat resistant) as well as the gasket on the bottom half of the stator cover to prevent the leak from continuing, even with a new grommet.

I don't see why you would have problems putting the cover back on by yourself...I had no issues with mine. The magnet does pull on the cover a little, but no enough so you'd have a problem.

Here's a procedure I wrote about testing and replacing the alternator stator(the stationary part with the wires)The magnetic rotating part is the rotor.

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. Also check from any of the three YELLOW wires to ground, this will show if arcing took place.

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. www.z1enterprises.com 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 will have to be removed to access the electrical connectors coming from the alternator, the left foot peg assembly and shifting lever will have to come off also.

__________________________________________________________
Alternator Stator Replacement On the Older 4’s

Source for replacement Stators:

A. www.electrosport.com (They have a trouble shooting page)
B. www.customrewind.com
C. www.rmstator.com
D. www.ricksmotorsportselectrics.com
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 Plexi-glass 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 (1)WHITE with RED stripe, this is the bikes main power wire usually 12 gauge in size.

B. One(1) 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(1) BLACK with YELLOW stripe wire, part of the ground circuits, maybe 16 gauge in size.

D. Three(3) YELLOW wires, maybe 14 gauge in size, 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.

Man, thats a very descriptive procedure. Thanks alot, I think I will be ordering the gasket for the alternator cover like tonite and performing this task as soon as possible.