I think I need a new voltage regulator.

GPzMOD750 wrote: i your description of where to hook up the out bound wires Nessism. The KZ has an extra wire that routes to a different set of fuses should just ignore all that and just run the lead either directly to the battery or the solenoid?

It might be more clear once I've actually pulled the old R/R but I'm a little unsure. Wiring always makes me nervous. If I add an inline fuse what size should it be?

loudhvx wrote: Sometimes kawasaki fuses the output to the battery, and sometimes they don't. (Unless the diagrams have a mistake, which is common.)

The main thing you want to avoid is having the battery fused, while the reg/rec can still power the bike. If the battery fuse blows, and the bike is at high RPM, the bike will probably still run, but will lose the filtering provided by the battery. This means the bike will be running without proper regulation. This leads to light bulbs melting and other bad things.

Fuse 1 is the usual position for the main fuse. Occasionally you will see a Kz with a main fuse in Fuse 2 position or Fuse 3 position (which could be a mistake on the diagrams (Kz550H2 for example) ).
Both Fuse 1 and Fuse 2 would be a good idea in case of a short to prevent wire melting, because both the alt and battery are power sources. Fuse 1 will handle almost all situations. The only thing it won't protect against is if there is a short in the reg/rec or if the wiring between reg/rec and battery gets shorted. Fuse 2, by itself also has vulnerabilities. Both 1 and 2, together will handle everything, but 1, by itself (which is the most common setup on Kz's), will handle most situations.

Fuse 3 position should never exist. This can disconnect the battery while the bike continues to run.