HELP!

1982 KZ1000 LTD. 29,000 miles. No electrical modifications except for the addition of a pair of Stebel Magnum horns. These were wired with a relay. The charging system is not working. Freshly charged battery (Load tested) reads 12.8 volts. At idle I read 11.6 volts and at 4,000 rpm I read 11.5 volts. Bike starts and runs great on freshly charged battery. All electrical devices work as they should. I have an FSM and I have a Clymers. I went through both manuals and checked everything as instructed and convinced myself that the reg/rec was shot. I have just replaced the reg/rec and in the process went through every connector (again), cleaned with contact cleaner and applied dielectric grease. I inspected the harness visually and saw no signs of chafing or breakage. I cleaned both ends of both the Pos & Neg battery cables and assured there was a good solid connection. I still get the same voltage readings! What have I missed? Oh, I have 50 volts on all three yellow stator wires at 4,000 rpm and with the connector unplugged and my volt/ohm meter set to the 20 scale I read .5 across any combination of the yellow wires. The only thing that doesn't seem normal is reading from each yellow wire to chassis ground I get readings from .6 to 1.7 while on the same 20 ohm scale.

HELP!

Are you getting power at the regulator? There are two wires that have power. 1 is the coming from the regulator through to the battery for charging, white and red striped.
The other is B+ at key on, Brown in my book, this also feeds many circuits like the gauges etc.
Then of course there is the ground, yellow/ blue striped. Of course I am sure when you checked the stator voltage it was at the 6 pin connector where the regulator plugs in?
Hope this is some help.

VTER, Consult your manual, but my experiance is all three of your stator output leads need to be at least 3 meg above ground. I'm thinking pinched wires or cooked stator. luck g

I had the same model bike (still do, but being rebuilt) in the mid to late 80's and I had a problem where the wires come from the stator to the outside of the cases. I believe this is all under the front sprocket cover. Anyway, there are connectors there where the wires can be disconnected or have been crimped together or something. One of mine was not making a good connection at that joint and would occasionally cause it to quit charging. It might be worthwhile to check that area carefully. I spent some money replacing things that didn't need to be replaced before I found the problem.

I had the same deal on my kz900. one of the wire in the stator cover was completely broken. didnt have much wire to work with either.i got wire couplings and shrink wrap and got it fixed though

VB, the voltage out of your Alternator seems high compared to what I read on my KZ650-B1.

My Rectifier output is about 1/2 the Alternator or:
... 28-30 Vac/2 = 14-15 Vdc.

Your Rectifier output of about 50 Vac should product about:
... 50 Vac/2 = 25 Vdc. Could this be a meter reading error?

See below the readings from my B1. Note that I have installed a Terminal Strip to provide Test Points. They are not protected by inline resistors so I have to be very careful not to short any of them.



Maybe yours works a bit differently... I don't know.

Best of success.
Bill

I think I have figured out my problem. This bike is possessed by a @*^$^&^# Evil Spirit.

A friend stopped by today and we tore into the bike. We opened up the harness and every wire was checked. I checked for continuity, did the "wiggle" test on everything. Everything checked out fine. Put back together it still exhibited the same problem, no increase in voltage across the battery terminals at 4,000 rpm. So we again went back to page one of the manual and started all over again. Now, with the connector unplugged, meter set to 200VAC I'm reading 3 to 4 volts on the yellow wires from the stator. Doing a resistance test I have .5 ohms across 2 wires but read OL when measuring between the third leg and either of the other two yellows. I also noticed that the left engine cover where the stator is mounted became to hot to touch after only 2 minutes of engine idling or revving to 4,000 to check voltages. 20 minutes after the engine was stopped, the cover was still to hot to leave a finger on more than a couple of seconds.

Anyone versed in exorcism? I'm not the sharpest knife in the drawer, but I am sure the stator checked out fine before, now it seems shot.

Wish I could help but I'm currently experiencing electrical problems w/my 79 GL1000 blowing 5amp fuses & killing the engine. I HATE electrical problems. As to the being possessed part, have you ever been to a Blessing of the Bikes gathering? Hey, couldn't hurt, right?

Actually I have been to one on my 550. It runs fine.... :blink:


I will gladly take the 1000 if I can get it to run! :laugh:

Electrical Gremlins SUCK. They will make you bald from pulling your hair out. :laugh:

Call me silly, but it sounds as if you have identified the possible faulty assembly. :silly:

So how much do you figure it's going to cost to replace the stator?

Best of success.
Bill

Have you used the trouble shooting guide at www.electrosport.com ?