Z1r Z1000 Replacement Rectifier wiring

Hi I have been scanning a number of Forums for days, have some answers but, nothing concrete

So to the details:
I have a 1978 D1 z1000 Z1R, US spec imported to UK, is it the model with the block connectors under the right hand side Panel, Blue is for the Stator and Green for Rectifier (RR), seems charging is ok but battery dies,
so went for an aftermarket rectifier advertised to as replacement for Z1R has the correct number of wires (5) see pic, my original see pic has 5 wires also, being black, green, brown, yellow, pink, to make it simple I cut
and patched the new RR wires into the original green block connector,

Connecting:
The Black to the Black wire on the new RR and connecting to the single free black wire on bike, as thought this was earth
The Brown to the Red wire on the new RR as thought this was positive into block connector
The Pink Yellow Green to the 3 Yellows on the new RR in block connector as I have read it needs 3 yellows which are for sensing, signalling

So the Question is this right
I don’t think so as it has not worked and now when the new RR is connected via the green block connector, the ignition key does not turn the motor off once running, I have to use the kill switch, if I remove the rr connection the ignition switch works

What wires should I join to what to make it work
Eg black to black, ….. brown to red etc

Any help greatly appreciated

Do you have a link for the rectifier you bought or a spec sheet or anything that would help us decode how it should be connected?

Unfortunately wire colours cannot be trusted when it comes to aftermarket parts.

hi Thanks below is the only blurb i have found
Wire length: 180mm
Input: 3x Yellow
+12V Output: Red
Ground: Black
the makers web link to te product is www.electrosport.com/street-bikes/kawasa...ulatorrectifier.html -
i brought it though the UK M&P site

From the diagrams the 78 Z1R has a separate rectifier. Did you remove it?
I thnk the "old r/r" may be a a voltage regulator only (not a r/r).
The new voltage regulator is a regulator-rectifier combo unit.

hi thanks I have not removed it
i wrote the to the manufactures and this what they wrote

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Those wire colors, black green brown yellow and pink, do not sound like the stock reg/rect's wire colors.
For our esr100, the 3 yellow go to the stator's 3 wires in any order.
black goes right to the frame for ground
red goes to battery positive.
since your bike isnt turning off correctly, thats a sign the red wire on the esr100 is not going to the correct wire on the harness. the wire it is going to must be behind the ignition switch, therefore when you turn the switch off, it doesn't stop the reg/rect from sending power to the bikes ignition system.

---

this site sells the same model as in the bike and they call it a regulator
www.cmsnl.com/kawasaki-1978-kz1000-d1-z1.../regulator_21066025/
maybe I have it all wrong but why sell an genuin part

confused totally

Hi I think i was on the wrong track and now understand , I have replaced the regualator with the rectifier, thanks, for helping me sense of this, will patch it all back in and start again - will let u know how i get on

report back you got me wondering now. :whistle:

leon

I think the new part replaces the reg & rec units on your bike.
You'll have to figure out the wiring, but the new part should simplify things.

Most KZs w a 3-phase alternator & reg-rec combo unit simply have 3 yellow wires coming from the stator & the r/r has 3 yellow wires, a power wire, a ground wire, & a brown sensor wire. The power wire on my bike connects to the hot side of the starter solenoid. The brown sensor wire is not used on some new reg/recs.

Hi martin came to the simalar conclusion, seems the Part #: ESR100 R/R replaces both the Rectifier oem 99996-1159 and Regulator 21066-025 on the D1 (see below links etc) where as the D2 has just the RR

so my view is I was trying to wire in the new R/R to the regulator space, so now just gotta to find the rectifier on the bike and then figure out the wiring and replace it, which i then guess i can dispense with the old regulator, wish a was an auto sparky

Part #: ESR100
Replaces OEM #: 99996-1159 21066-025
www.electrosport.com/street-bikes/kawasa...regulator-rectifiers
part fiche
www.cmsnl.com/kawasaki-1978-kz1000-d1-z1...t/66424.html#results

hi still having issue, has anyone replaced a separate reg/rec with a combination rr unit, mine is a 78 kz1000 D1 but I notice on other wiring diagrams that other models were put together the same way ie Z1 73-74

I guessing I need to plug the new rr's 3 yellow wires in the 3 coming from the generator and the black to Earth red to positive as look at the diagrams the separate req/rec and just wired to via the blocks

Any help appreciated

I suggest you contact the folks at the link below for a solution. I found them to be very helpful. I am using one of their rectifiers and it works perfectly. Ed

www.oregonmotorcycleparts.com/Products.html

See following links for info.

www.z1enterprises.com/ItemDetails.aspx?i...KZ1000&item=RI10-306

www.z1enterprises.com/ItemDetails.aspx?i...f1000&item=PM81-4081

www.z1enterprises.com/ItemDetails.aspx?i...n+unit&item=RI10-515

Installed the plug-in style on KZ900 many years ago and still performs perfectly.

Good Fortune!