The A.C. Generator(Alternator) is made up of two basic parts: 1.The Rotor, containing magnets which is secured to the crankshaft, spinning around the wire windings of the 2.Stator or stationary part of the alternator.
Have you tried this test?
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. 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.
9. Check the wiring coming out of the grommet as there have been situations where the wires were damaged causing a short.
10. 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.
The website
www.electrosport.com
has a troubleshooting page for testing.
My shop manual for my 82 GPz1100 B2 lists using an OHMETER for resistance checking. Set the OHMETER to OHMS X 1 and test all three combinations of the output wires(1-2,2-3, and 1-3)in my case the reading should betwen 0.36 to 0.54 OHMS(yours may be different).
