TOPIC:

RR just came in so I might go ahead and splice it in. Batt fully charged, with old regulator plugged in, I'm getting about 12.65 volts. With regulator unplugged, after fixing the rectifier ground issue, i'm getting between 15-17 V, so regulator seems screwed(?) Shouldn't I be getting about 14.5 with a working regulator at idle?

Loudhvx mentioned that some systems are ok with the 3 yellow wires being spliced in in any order-
I'm trying to sort out if I can match exactly which ones match my old regulator-I'll check out the picks of the one piece sold on Z1 and see if coming out of the case the colors match, and if the picture of their connector is good enough to determine which yellow goes to which spot on the connector-

On my regulator connection, the 3 are
Light blue, pink
And yellow

Pic of the new one?
Steve

I happen to have the old plugin jumpers that were behind the connector block. Looks like the pink, light blue and yellow all go to the stator. I'm uploading a clip of them now.
Steve

I really think you'd be better off with a modern system but here you go. I wouldn't cut any wires until I knew it was the problem. Maybe make up some pigtails?
Steve

I case you got a combo unit.
Steve
Old Kaw Man's drawing

Thanks Steve,

I went ahead and spliced new connectors in line, and kept my old regulator harness and connector so it worked pretty well-
The only question was the 3 yellow wires from the new RR, impossible to tell which of the 3 went to pink, light blue and yellow. But, everything seems to be working, now with the Ninja500 RR connected I'm getting 14 + volts
Earlier I posted before the new RR arrived, I was able to clean the ground from the stock rectifier and immediately saw 17 V with stock regulator disconnected. But old regulator was suspect, so as soon as the mailman got here with the new RR I started splicing things.

Looks like it's working well. I'm tucking things in but it's already night time, I'll clean things up tomorrow. The Ninja RR is small enough and I mounted it next to old rectifier for now-
Thanks for all the help and suggestions, much appreciated.

Nice job finding that bad ground and confirming the manual's test indeed works as expected.

Glad to gear the ninja reg/rec is working. Great up close photos by the way.

And yes, it does not matter which stator wire goes to which yellow wire.

You might want to watch this.

hardrockminer wrote: You might want to watch this.

Yes I did see that video, thanks
It's looking like my EX500 RR worked pretty well, will report if something else comes up.
And even though I had my 2 year old AGM charged, load tested, I even bought a new one to rule that out. Batteries Plus then allowed return and full reimbursement, buying online involves return shipment costs, etc.
All the testing I did was according to factory manuals-I have both 900 and 1000 manuals
So final verdict is my ground wire on rectifier was not grounding. Fixed that, but regulator was probably failing. Since I had bought a more modern EX500 combination RR, I felt it better to just put that in. A stock regulator is hard to find, even on eBay prices were ridiculous-

Thanks again

Glad to hear you were able to source your problem and fix it.

Yep...stock regulators are expensive if you can find them. I keep a spare in case one of my Z1 regulators fails. It amazes me that they are over 40 years old and still functioning.