My kz 400 rectifier's wires fell apart in my hand

Ok, so i went to start rewiring my kz 400 bar hopper bobber bike. When i went to pick up the rectifier the white wire broke off completley clush with the unit itself. So i was more than ticked off you could say. I ended up ordering a universal regulator/rectifier combo unit from Rick's motorspot electric's, here is the link to the one i bought, www.ricksmotorsportelectrics.com/proddet...pmc=NzZLYXdLWjQwMA== . I hope it works. Here is the wiring diagram i am following, my electronic guru of a friend is helpinh me with it, with out him i would be lost.......lol. Me and wiring are natural enimies, but after tackling this project, i wont be so intimidated on future wiring jobs. Im going with a bare bones wiring system, head light, tail light, and all the charging stuff needed. Im glad i found this rectifier/regulator combo unit, it will help me out with a nice clean look.

Does anybody know how this wiring diagram will differ with the regulator rectifier combo unit, instead of them being seprate units?

Well after fiddling with this thing for a week and not having luck, i finnaly came down to the conclusion that the battery was bad. I got a new one, put acid in it, and charged it. Here is what happened, i went to hook up the battery cables, i hooked up the negative cable.....all was good, then i went to hook up the possitive cabe, and it arched and the ground wire started to smoke. I obviously got something wired backwards.......any advice?

Likely no help regarding the short.

But imo it's better to FIRST attach the positive battery cable to the positive terminal (no spark).

And SECOND attach the negative cable.

Don't know exactly why this is, but seems to reduce the tendency to spark when attaching the second cable.

Good Luck!

Ya i heard that to. I dont know why that is? I dont think thats why my ground wire started smoking though?

oldkaws4ever wrote:

Does anybody know how this wiring diagram will differ with the regulator rectifier combo unit, instead of them being seprate units?

I believe there is a difference!! I know that early KZ650's had a two piece unit and can not use the newer one piece combo's.

A lot of people are buying units from Oregon , call the guy up and ask him. www.oregonmotorcycleparts.com/rectifiers3p.html

This would be the units you need from Oregon:
regulator VR3-KZb $50.00
rectifier R255a-KZ400 $45.50

If it's not too late don't put the juice into your present unit because you may have to return it or sell it, I don't think it will work.