Bad stator or something else?

The charging system in my 75' kz400D left me stranded about a month ago.  I went through the system, testing everything the best I was able.  Some of the resistance measurements were a little higher than the factory shop manual listed.  

The stator measured 1 ohm between all 3 coils with nothing grounding.  The factory manual lists .4 - .6 ohms.  I also did an AC output test at idle rpm (1200) with the field coil dead and live.  The dead output was .3 - .5 volts and the live output was 3.5 - 5.5 volts.  Definitely  lower than I've heard it should be.  

I don't have exact numbers on the field coil but it was within spec and not grounding.

The rectifier diodes measured within spec with no back flow bleed.  Around 530 on all three.  Im not aware of other tests i can do while not running.  

The regulator tested slightly above spec on both resistance measurements.  114 on the 100 ohm spec and .6 on the .5 spec.  

Im trying to figure out what I need to replace.  With the regulator and rectifier both being original they are probably close to done if not already.  I was thinking about a ricks electric combo reg/rec.  

The stator is putting out low AC voltage from what i can tell.  A new one is around $250 so i want be sure its bad before pulling the trigger.  

what are your thoughts?  Is anything obviously bad?  Are there any additional tests i can run on the different components?  Im on a pretty tight budget so i want to stick with the bare minimum initially and then upgrade other components down the road.

I will chime in since no one else is biting.  Based on my research, the stator should be producing around 20 AC volts at the bare minimum.  With mine making 3-5 volts, it's clearly not up to snuff.  Im guessing there may be some internal shorting or resistance.  The 1ohm reading on all three coils is a bit high as well.  Im going to make the call that at the vety least, i need a new stator.

You don't appear to have mentioned the ignition live to the regulator that excites the field coil (voltage check) you also don't appear to have confirmed the regulator ground is good with a voltmeter ?

I tested the brown 12v supply wire for the regulator and im getting 12v at the point where the wire connects to the regulator.  My testing was done with the brown and green wires disconnected from the regulator and jumped so the full voltage was going to the field coil. 

I do need to check the ground for the field to ensure the full voltage is flowing.  Something else occurred to me regarding the stator.  Im getting uneven measurements that are consistent between loaded and unloaded field coil.  .05 v unloaded shows 5 v when loaded.  .04v unloaded shows 4 v when loaded.  .03 v unloaded shows 3v when loaded.  These uneven measurements despite being consistent make me wonder if the stator has some issues regardless.  Can a stator produce uneven voltage and still be good?

In my way of thinking,not saying I am correct. If you have by passed the voltage regulator and provided full battery voltage to the field coil and only get the very small voltage results, I would think either the field coil or the stator is not doing it job correctly. 

 

How does the field coil resistance compare to factory spec ? if the field coil isn't working correctly you won't get the required output from the stator

Bypassing the regulator and jumping the brown 12v supply wire to the green wire was the procedure outlined in the kawasaki factory manual.  I will double check the resistance on the field coil and also the ground circuit and report back. 

I had an issue with the headlight causing a voltage drop in the brown supply wire.  I fixed the ground on the headlight and that solved that issue.  I did test the stator after fixing that issue to be sure it didn't change the results.

Field coil test results

Voltage drop at brown supply wire .3v

Generates magnetic field when charged
Resistance measures 5 ohms.  Spec in the manual is 3.8 - 5.8 ohms.

Isolated the field coil and connected positive battery terminal to green wire.  Measured no voltage between ground and negative battery terminal.

Measured 2.5 amps of current through the field coil

Voltage drop of .57v measured over the field coil circuit when using a dedicated ground wire for the field coil circuit.