Charging on my 1980 'KZ650

Hi all,

I nearing the end of the re-commission of my KZ650 E1 LTD 1980, over in Nepcote, West Sussex, UK.

When I start it up it feels a bit lazy so I keep it on a charger in the workshop, but when I've been out riding its a bit reluctant to start.
It has a new battery fitted.
Not started I get 12v at the battery, but on starting this does not move and stays around 12V. When I unplug the rota and stator and run it drops to 10v, so the rota stator are supplying some juice, but maybe not enough.
Looking at YouTube videos I should get 14v when the bike is running.
The reg/rec says SH on the back and has 5 wires - 2 yellow and one black in a block, then a separate brown and a separate white / red.
This does not match the YouTube videos all of which seem to have 3 yellow diode wires.

I cleaned up / replaced all the connections from the rev/rec, the battery to starter solenoid and the battery to earth lead to frame.
The above readings are taken after I cleaned and replaced some connections.

Do you think the rev/rec needs replacing - how do I test it?

Thanks - Paul.

There is a recent discussion about testing them, but I have not found it. In the mean time, here is some reading that might be useful to you.

www.kzrider.com/forum/24-wanted/606270-b...-buy-a-new-regulator

Do not worry about the YouTube videos that show different numbers of wires. There were several different charging systems used on the KZ650 models, so you need to start by focusing on the one for your exact year and model bike. The first link below shows wiring diagrams for the different models.

Instead of trying to guess which part may be defective you need to run diagnostics to positively identify the condition of each part. The Kawasaki Service Manual has instructions. I highly recommend you buy one for your exact year and model bike, but until then you can find one at the second link below. Ed

diagrams.kz650.info/wiring/WiringDiagrams.htm

www.kzrider.com/modules/ServiceManuals/K...l%20KZ650%201981.pdf

According to the wire diagram, you should have a 1-phase , permanent magnet system. Your description matches that. 2 yellow. 1 red. 1 black. 1 brown.

The brown wire is what the regulator uses to sense battery voltage. The earlier 1-phase systems did not have this wire. The later 3-phase system do have it, but also have 3 yellows.

Do you have a stock ignition as well?

Ed - that link does not show the E1 LTD which is single phase.

Do you have a link to the E!?

Thanks - Paul.

Take another look. The KZ650-E1 wiring diagram is there. It's at

diagrams.kz650.info/wiring/images/KZ650-E1.jpg

Ed

Ed - thanks - I have the wiring diagram - I was after the E1 manual? Thanks Paul.

No eBay APP ID and/or Cert ID defined in Kunena configurationSorry, I misunderstood.

I don't have an electronic copy of the manual that includes the 1980 KZ650-E1, but they are sometimes available on eBay. The part number for the manual that includes the E1 supplement is 99924-1007-03. You can use that number to search eBay. The back cover of the manual shows the list of models it covers. Currently there is one out there at:



Ed

The tests are pretty basic. And actually, some manuals have the expected test results incorrect.

For the 1-phase stator test:
Make sure the battery has a good charge on it.
Disconnect the reg/rec. Then attach an AC voltmeter to the two yellow wires coming from the stator.
Run the bike up to 4000 RPM. The voltmeter should reach about 75vac.

Some manuals incorrectly state 55vac as the target voltage, but that is for one pair of yellow wires on a 3-phase system.

You can also do a standard diode test on the reg/rec using an ohmeter, but that is more tricky and not very conclusive, unless there is a dead short. But if there was a dead short, it would be smoking and wires would be melting.

That manual in Ed's link seems pricey, but that might be pretty rare, as the 650 E1 does not get mentioned on Kzrider often. We usually see B's, C's and D's.

Ed, Loudhvx - thanks for the info.
Yes the manual would cost me $100 plus to get it to the UK - bit more than a download.
This site looks good but misses the E1...
www.zedrider.co.uk/service--owners-manuals.html
I'll run the check you detail.
Thanks - Paul.

biker_smith wrote: Ed, Loudhvx - thanks for the info.
Yes the manual would cost me $100 plus to get it to the UK - bit more than a download.
This site looks good but misses the E1...
www.zedrider.co.uk/service--owners-manuals.html
I'll run the check you detail.
Thanks - Paul.

Ouch! That really is expensive. Here are images regarding the charging system; they are from the 1980 KZ650-E1 Supplement. Ed

Thanks for the scans Ed.

For anyone reading those pages from the manual, be aware they are defining current flow as the same direction as electron flow. It is more common to see current flow defined as the opposite direction from electron flow. You can define it either way, but it is more common to see current flow as the opposite of electron flow.