TOPIC:

Hi guys , new member here .
I'm having the issue with overcharging on my 77 kz1000 LTD as some other members have . I have the Dyna S ignition that has been on the bike for several years , I just put a complete wiring harness on the bike due to the original being a rats nest. I added a new regulator /rectifier combo, after starting the bike and going up and down my street once the bike started to smoke , the Reg/rectifier burnt out and shot a small flame out of it, the bike did not blow a fuse, I put my old separate reg/rect back on and it started right up but is putting out to much voltage .....I got an OEM style reg and put that on .....same thing . I ordered a combo unit from Ricks electric.....same thing .
The stator test good
the rectifier test good
the regulator test good
all grounds are new and good
the battery is new . I've disconnected most of the non essential electrics (lights and oil , neutral; switch , )
I cannot figure out what the problem is , the bike runs good but could it be voltage leakage from the coils , something is telling the regulator to keep putting out excess voltage ?
Thanks for any help !

Sounds like a wiring issue. The stator should feed directly into the R/R. Bypass the factory harness. Output power from the R/R can feed into the fuse block, again bypassing the harness or tap the harness and look for voltage loss in the circuit. R/R ground should be to a solid frame point or direct to the battery. Don't trust the factory wiring, particularly with regards to grounds.

Sound like a open ground...

Nessism wrote: Sounds like a wiring issue. The stator should feed directly into the R/R. Bypass the factory harness. Output power from the R/R can feed into the fuse block, again bypassing the harness or tap the harness and look for voltage loss in the circuit. R/R ground should be to a solid frame point or direct to the battery. Don't trust the factory wiring, particularly with regards to grounds.

Its epidemic...

I've tried both ways , factory set up with brown wire that had 12v running , and the aftermarket reg/rect which is wired (three yellow) wires from stator to reg/rect, two green from reg/rect to battery ground, two Red from reg/ rect to battery Pos , (this should bypass most of the harness ) I also have new ground wire from battery to engine block and smaller pigtail ground wire to frame .
I don't think I have bad coils , the bike starts and runs good , also I watched the Kawasaki factory electrical training youtube video and the say the battery should put out between 16 -20 volts ? but elsewhere I see no more than 15v tops ?

Pics of what you're working with would help.
Steve

OK , The ground wire in the harness that comes out at the electro bracket for the regulator (connects to black ground from factory reg), when I unplug that from the harness and hit it with the test light( from harness side) I have a complete circuit with the key off and on ? is this correct . I'm testing from battery pos , to ground (wire)

Attn. Ed
Here's a group of pics taken while examining my bike charging issue with a voltage meter.

That's a good illustration of measuring the system voltage drop directly.

By the way, the drop should not be zero, that would defy physics.

This is how I wired my R/R, I like it simple.
This is the easiest and the most bullet proof way to hook up the Mosfet Regulator/Rectifier

kaw-a-holic

I'm going your way...what a great suggestion!

daveo wrote: kaw-a-holic

I'm going your way...what a great suggestion!

I will get you some more picks on how I wired it in. For my 77, I ran new wires from the stator to the R/R. That's the 3 yellow wires you see coming from my R/R. Bat lead will go to my resetable breaker then to the bat. Negative will go straight to battery.