Charging system upgrade?

Hello all,Ive got a kz1000 that I've upgraded the suspension,brakes,& lighting.I notice that my charging system doesn't start charging till around 3000 rpm & maxes around 4000.My headlights are not as bright as they should be,on high beam.Also my signals won't flash if battery isn't charged good.Does anyone know a way to make this old system charge at a lower rpm range?Any help is much apreciated.

I am considering modifying my lighting systems, and most likely be running into the same problem, so I am going to subscribe to this thread, and if I find anything I will let you know!

The bulbs I'm running are off a buell lightning.There h7 55watts.The low beam alone is 3 times brighter than the original kz.When I turn on the other light they don't get brighter,& a more yellow tint.I just got some of those hid kits,there only 35watts.I may try running a little trickle charger all the time.

Go to www.electrosport.com as they make overwound stators that will charge at lower rpm's. You should replace the regulator/rectifier too. as they start to lose the ability to function after a few years. Electrosport and other websites sell good replacements:

Stators, Regulators & Rectifiers
www.rmstator.com
store.prestoliteperformance.com/accel-mc...z1000-1100-1300.html
Kawasaki 77/78 1000A. www.denniskirk.com/jsp/product_catalog/P...tId=&mmyId=10274
Kawasaki 79 1000ST.
www.denniskirk.com/jsp/product_catalog/P...atId=&mmyId=1656
www.customrewind.com (They can rebuild your stator for you).
www.regulatorrectifier.com
www.oregonmotorcycleparts.com (not sure they have stators)
www.accel-motorcycle.com/
www.tpe-usa.com/ (Tim Parrott Enterprises)

If it was anything like mine, I noticed i had a charging problem similar to yours. But i found that mine was only charging on two legs of the stator and then when the second one went out it wasnt enough to do anything. I purchased a stator from elctrosport as suggested by mfolks. They do make a great stator. I have been real happy with it after it all got settled. My bike is a 80 with mk11 style stator which is diffrent then the earlier KZs. So they had problem finding me the right stator. Took all together little less than a month to get it all straightened out. I had to end up sending mine to them. Then they tried to tell me it was off a kz750. Well turns out there the same i guess, cuz it bolted right up but i had to cut the wires and install the correct oil seal and solder them back. But now i realize how bad my stator wasnt charging. All my lights are real bright now. It also would really wing the engine over with the starter. But now not so much. Now its struggles to start with the starter, now that the new motor is in.

I'm going to order a regulator/rectifier from electrosport.I didn't see any broken winding in the stator.Ive had them break before.I prob shouldn't be cheap,but I can always get the stator.I'll post the results.

Power stroke fan,did you use the stock advancer with the springs on your ignition.

I did. But the dyna ignition was already installed when i bought the bike years ago. But since mines a 80 it should of came with a electronic ignition factory. I have been told that the factory breakerless ign actually pulls less amps. Also if you have a multi meter you can test the legs to see if they are charging correctly. The wires was not broke, but they were in bad shape at the factory bullet style connectors. The stator wasnt charging on all 3 legs.

I'll check the wires at the connector.Mine has the blue connector at the fuse box.That stator came off a 76 I've.It may be crap.I thought it just had one wire on each side of the winding.

Did you run diagnostics on the regulator / rectifier? If it has a problem you may experience the symptoms you described. Here's a place that sell high quality units at good prices. I have one of their rectifiers on my KZ650 and it works perfectly. On my KZ650-C1 the regulator and rectifier are separate units, but they sell all flavors. Ed

www.oregonmotorcycleparts.com/Products.html

If not already done, would assure integrity of the ground connection where the negative battery cable attaches to rear of the engine.

Would also assure that the regulator/rectifier is well grounded via the black/yellow wire.

Good Fortune!

I will check the grounding.I have a ground from the starter cover to battery.Then one to the battery to battery box.I had that box powder coated,so that's a possibility.I haven't got to put my hands on it yet.