82 KZ550D1 Voltage regulator issue

Dears,
I have jammed with my project and need support to move forward.
Story is that i'm preparing full rewiring of my KZ550, and replacing some of electrical parts.
I have stuck with Voltage regulator (the one that i have is in poor condition, but i have an issue with finding new one.

if i look for parts catalog it seams that it should have 3 faze rotor and applicable regulator, but on the bike there is 1 faze rotor (2 yellow cables). regulator have 4 cables in the plug (black>yellow>brown>yellow) and additional red one.
i can not find any ware new regulator like this.

Any one knows what is going on is it a problem of the poor catalogs, ore there was some experiment on my bike done by previous owner??

Photo is original, some reproductions are black.

73z1 thanks,
This is 6V - it needs to be 12V, and there would be also one wire missing - the brown one.

No eBay APP ID and/or Cert ID defined in Kunena configurationYou don't really want to get a 40 year old one if you can help it.

The Kz550D1 is a 1981 Gpz model (1982 would be an H model Gpz). Are you sure that's what you have? Regardless of what the title says, Kawasaki identifies the D1 as a 1981 so that is what you would look up for getting parts etc. That model is a one-year only model.

I'm asking about the precise model because the D1 should have had a 3-phase system. Some or all 1980 models have 1-phase systems.

1-phase has 2 yellow wires.
3-phase has 3 yellow wires.

Maybe someone swapped out your engine? Does your engine have an oil cooler?

You can easily swap the entire system over to 3-phase by getting a used 3-phase stator and a 3-phase reg/rec.
Since you are already re-wiring, it will be easy to add the third yellow wire.

For the reg/rec, the cheapest solution is to get a used, genuine Kawasaki factory reg/rec from an early 2000's Ninja 250 or 500 model. They can be had reliably for $10 to $15. They have the same wire combination, but you have to splice the connectors.

You can get aftermarket reg/recs but they usually run closer to $100. I don't consider them to be more reliable than the factory units, and often they won't have much warranty to them once installed.

Then there is a newer type called a series-pass reg/rec. That's the Shindengen SH775. It works differently from the older reg/recs. It reduces the current draw on the stator and reduces heat in the stator. It's pretty expensive and there are counterfeit ones flooding the market so beware. I don't think it's necessary on the 550's. 550's seem to have pretty solid charge systems to begin with.

Here's a Ninja 250 reg/rec example. 60-day money back guarantee, but for $8.50 is it even worth returning?

Several years ago after seeing a similar topic by loudhvx, I installed a voltage regulator from a low mileage 2007 Ninja 500. my motorcycle has a 3-phase stator w 3 yellow wires. The reg-rec terminal pins were reversed, so I cut them off & installed new. I already had a Harbor-Freight ratcheting crimper but the crimp dies were wrong, so I got a set of open barrel dies off of amazon.com >> the crimps are the same as stock & very strong. I got the terminal pins from CycleTerminal.com & also a new plastic connector as the old one had crumbled. Z1Enterprises also has the stuff. CT has a ratcheting crimper w the correct dies for about the same price I ended up paying in total for the crimper & dies.

.....

@laudhvx about the mode you might be right. in the papers it is stated KZ550 only. it have been produced on 82, and there was GPZ emblema on the side covers, but as the frame nr starts with KZ550d.... i thought mat it is "D" model. possibly wrong deduction . and yes - there is a small oil cooler.

Speeking about electrical system intself, one more question if i would go for 3 phaze. stators from what models schould i look after and if it is possible that it will be plug and play (in terms of mointing fitting the cover etc.?

Gutowski wrote: @laudhvx about the mode you might be right. in the papers it is stated KZ550 only. it have been produced on 82, and there was GPZ emblema on the side covers, but as the frame nr starts with KZ550d.... i thought mat it is "D" model. possibly wrong deduction . and yes - there is a small oil cooler.

Speeking about electrical system intself, one more question if i would go for 3 phaze. stators from what models schould i look after and if it is possible that it will be plug and play (in terms of mointing fitting the cover etc.?

Every Kz550 after 1980 should have 3-phase stators you can use.

1981 Kz550A2
1981 Kz550C2
1981 Kz550D1
1982 Kz550A3
1982 Kz550C3
1982 Kz550H1
1983 Kz550A4
1983 Kz550C4
1983 Kz550H2
1983 Kz550M1
1983 Kz550F1
1984 Kz550F2

And I think Zx550A models have stators that should work fine.

Do you have good photos of the bike and engine?

All Gpz engines have Kz550Dxxxxxxx engine numbers.
All Gpz engines came with 3-phase stators.

Kz550D1 (Gpz) models are from 1981, but could be built in 1980 or 1981. They might have been first registered in 1981 or 1982. Some places go by registration, not model year.

good photos - not realy, any photos.. hmm i have some from the day i bouth it.
there is some "nice" tuning done on it but what can you do

That is definitely a 1981 Kz550D1 Gpz. It's the first Gpz 550 and the only one with dual rear shocks.

It should have come with a 3-phase charging system which means 3-phase stator with 3 yellow wires. I don't know why someone would change it to 1-phase.

Anyway, you should restore it back to 3-phase with a stator from any of the Kz550's I mentioned.

That's a nice looking bike. I love the color.

Here's mine.

laudhvx SO COOL
At this time mine is dismantled to pieces and will look a bit diferent after i finish it. hopefully it will look better not the oposite site
Colour is still a question mark but i think it will be something less eye catching, or even blinding

Thank for info and advice. decision take i will go for 3f.

I have found localy stator that is described as equwqalent for parts: 21003-1040, 21003-1327
and fiting to KZ 1000 81-01 r., KZ 1000 P POLICE 82-01 r., KZ 1000 J 81-83 r., KZ 1000 K 81-82 r. KZ 1000 R 82-83 r. KZ 1000 M CSR 81-82 r. KZ / GPZ 1100 A, B 81-83 r. KZ 1100 D 82-83 r.
KZ 1100 L 1983 r. ZN 1100 / ZN1100B / GPZ1100 84-85 r. ZX 1100A 83-84 r. ZX1100 83-84 r.
dimentions are
outsite fi 102 mm
isite 37,8 mm

is it possible that this are the same parts, partzilla defines stator to kz550d1 as 21003-1038 so the number is different but i think it is worth t ocheck with formum knowladge from experience i know that this catalogs are not always acurate (whan i was looking for new brake main piston it apper that kz1100 police pieces fits, and the one that where pointed in kawasaki catalog for europe not

Kz550 or Zx550 stators only or maybe Zr550.

Not 650, not 750, not 1000.