A 3 month old battery loses its charge with 15 miles
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Re: A 3 month old battery loses its charge with 15 miles
04 Aug 2026 11:35
Thanks.
It’s wet.
It’s wet.
1981 Kawasaki KZ440-A2
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Re: A 3 month old battery loses its charge with 15 miles
04 Aug 2026 11:41
If the dowels will come out without damaging them it would be easier
1982 KZ1000 Ltd
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www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 03:13
Hi folks.
I sourced a replacement gasket for the stator. As you will see from the photo, it is marked on both sides with a white residue. The seller told me it is new, by which I think he meant unused, and my guess is this residue has built up over years in storage.
I can wipe some of it off with a damp cloth. However if you can offer any advice on whether the residue can be considered unimportant and can be used as is, or if it must be fully removed, or a.n.other nugget of advice, I’d be very grateful. Many thanks.
I sourced a replacement gasket for the stator. As you will see from the photo, it is marked on both sides with a white residue. The seller told me it is new, by which I think he meant unused, and my guess is this residue has built up over years in storage.
I can wipe some of it off with a damp cloth. However if you can offer any advice on whether the residue can be considered unimportant and can be used as is, or if it must be fully removed, or a.n.other nugget of advice, I’d be very grateful. Many thanks.
1981 Kawasaki KZ440-A2
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 03:33
Personally I would install "as is" trying to clean it it possibly do more harm than good
1982 KZ1000 Ltd
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 03:48
Sometimes factory gaskets have a "coating" on them. It's to aid sealing.
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 04:08
Thanks. I have wiped it already with a damp cloth. I hope that hasn’t affected it’s integrity 🤞
Current state:
1. I need to clean the copper of the two stator wires I’ve cut back (I believe vinegar is helpful in this) before soldering new wires to them to exit the stator cover.
2. Extend the new wires with in line plug/socket which will then connect to a new 3-way plug at the RR. I don’t have spare yellow wire with enough length to reach the RR in one hop.
2. Finish cleaning the mating surface of the stator cover, position the gasket, then reattach to the bike.
2. Replace the oil lost after removing the stator cover. I think most of the bike’s oil came out.
3. Bench test the replacement RR.
4. Replace the plug on the RR with a new plug.
5. Connect everything back up.
6. start her up and measure the voltage on the battery at 4000rpm
7. cross my fingers 😁
Current state:
1. I need to clean the copper of the two stator wires I’ve cut back (I believe vinegar is helpful in this) before soldering new wires to them to exit the stator cover.
2. Extend the new wires with in line plug/socket which will then connect to a new 3-way plug at the RR. I don’t have spare yellow wire with enough length to reach the RR in one hop.
2. Finish cleaning the mating surface of the stator cover, position the gasket, then reattach to the bike.
2. Replace the oil lost after removing the stator cover. I think most of the bike’s oil came out.
3. Bench test the replacement RR.
4. Replace the plug on the RR with a new plug.
5. Connect everything back up.
6. start her up and measure the voltage on the battery at 4000rpm
7. cross my fingers 😁
1981 Kawasaki KZ440-A2
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 04:21
When you clean the stator wires just use your razor blade dragging it towards you to scrape off the "shalac" laquer that is on the wire so you have clean shiny copper. I used the end cut off of an uninsulated crimp connector to hold the yellow wire in place on the stator wire then soldered the whole thing (make sure you get it hot enough for the solder to flow)
1982 KZ1000 Ltd
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
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Re: A 3 month old battery loses its charge with 15 miles
Yesterday 05:15
To expand on Wookie58's recommendations a bit, I would be reluctant to use anything acidic (vinegar, acid solder flux, etc cetera) near any wiring. The acid could wick up the wires, even getting under the insulation and causing corrosion to start in the new connections. That is why the solder flux for electronics is non-acidic.
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1981 KZ1000 LTD slowly moving toward resurrection
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1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough
www.kzrider.com/forum/11-projects/620336...amateur-build-thread
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Re: A 3 month old battery loses its charge with 15 miles
Today 07:54
I’ve previously tried 600 sandpaper but only got so much off. I’ll try the razor blade. I have very little flex to work with tho so it very difficult to work on it. And the screws holding the bracket will not budge either by hand or with an impact screwdriver. I’m reluctant to force them because it’s clear the screw heads will chew up easily.
1981 Kawasaki KZ440-A2
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Re: A 3 month old battery loses its charge with 15 miles
Today 07:55
Thank you for that advice. I had the vinegar bottle at the ready and was just figuring out how to dip such short wires into a wee bowl of the stuff.
1981 Kawasaki KZ440-A2
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Re: A 3 month old battery loses its charge with 15 miles
Today 08:01
Are you using JIS bits in your impact driver ? before trying to undo find a flat drift (you could use an extension from a socket set) position it squarely on the head of the screw and hive it a good smack (this relieves some of the tension on the threads and makes them easier to undo)
1982 KZ1000 Ltd
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
www.kzrider.com/forum/11-projects/617631...-82-begins?start=192
kzrider.com/forum/faq-wiki/616810-electr...-fault-finding-guide
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