A 3 month old battery loses its charge with 15 miles

  • Jimbo68
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Re: A 3 month old battery loses its charge with 15 miles

29 Jul 2026 13:40
#926240
Can anyone answer my q: “can I replace this yellow cable readily where it terminates on the alternator?”.

i don’t have specialist tools to remove the alternator so if i can’t tidy that short yellow wire within the alternator compartment, there is no need to remove the alternator’s cover.

thanks again everyone. 
1981 Kawasaki KZ440-A2

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  • TexasKZ
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Re: A 3 month old battery loses its charge with 15 miles

29 Jul 2026 14:18
#926241
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/forum/11-projects/620336...amateur-build-thread

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  • Nessism
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Re: A 3 month old battery loses its charge with 15 miles

29 Jul 2026 15:25
#926242
You need to remove the stator cover and make a proper assessment of the wires condition.  Use an impact driver, the type you hit with a hammer.  If the cross point is totally wrecked, use a dremel cut off disc and cut a slot, then use a flat blade tip in your impact.  The screws should come out.  

Most likely, you can simply splice a new section of wire onto what you have now.  Solder and use shrink wrap, or use some premade butt-connectors.  

There should be no more than 1 ohm between any two pairs of the stator wires.  With the bike running, and the wires loose, about 80 VAC, between any two wires.  

Assuming the stator checks out, I'd buy a used Shindengen SH775 R/R.  These are super robust units that will protect your stator from overheat damage from shunted current.  You can find these units for less than $50 on eBay.  Just be careful to not buy a fake; buy a used unit where you can read "SH775" printed on the top fin.  To find one, search eBay for 4012941 or 71001103, toggle used, then pick one out.  

[img
SH775 Install by nessism , on Flickr

 
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  • Jimbo68
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Re: A 3 month old battery loses its charge with 15 miles

Yesterday 02:37
#926250
Great thanks Nessism. 

Unless I’m mistaken my multimeter won’t allow the measurement of sub-1 ohm, or I’m missing something? Any suggestions please? 
1981 Kawasaki KZ440-A2

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  • Wookie58
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Re: A 3 month old battery loses its charge with 15 miles

Yesterday 04:37
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Put it on the 200ohm scale at the bottom and it will read 0.@@@

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Re: A 3 month old battery loses its charge with 15 miles

Yesterday 08:32
#926272
It will not read sub 1 ohm accurately but what you are checking for is that it does not read over 1 ohm.
Your meter will probably have some lead and contact resistance. For low ohm testing, I usually short my leads together and subtract that reading from the reading of the component I'm testing.
1997 ZL600
94 KE100
82 KZ305
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Re: A 3 month old battery loses its charge with 15 miles

Yesterday 09:55
#926278
Most digital meters will "zero" if the leads are held together (analogue meters have a knob to adjust zero)

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