A 3 month old battery loses its charge with 15 miles

  • Jimbo68
  • Jimbo68's Avatar Topic Author
  • Away
  • User
  • User
    Registered
  • Posts: 123
  • Thanks: 9

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

04 Aug 2026 11:35
#926474
Thanks.

It’s wet.
1981 Kawasaki KZ440-A2
The following user(s) said Thank You: Wookie58

Please Log in or Create an account to join the conversation.

  • Wookie58
  • Wookie58's Avatar
  • Away
  • Moderator
  • Moderator
    Registered
  • Posts: 6648
  • Thanks: 4197

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

04 Aug 2026 11:41
#926475
If the dowels will come out without damaging them it would be easier 
The following user(s) said Thank You: Jimbo68

Please Log in or Create an account to join the conversation.

  • Jimbo68
  • Jimbo68's Avatar Topic Author
  • Away
  • User
  • User
    Registered
  • Posts: 123
  • Thanks: 9

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

Yesterday 03:13
#926504
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.
  
1981 Kawasaki KZ440-A2

Please Log in or Create an account to join the conversation.

  • Wookie58
  • Wookie58's Avatar
  • Away
  • Moderator
  • Moderator
    Registered
  • Posts: 6648
  • Thanks: 4197

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

Yesterday 03:33
#926505
Personally I would install "as is" trying to clean it it possibly do more harm than good
The following user(s) said Thank You: asphalt900, Jimbo68

Please Log in or Create an account to join the conversation.

  • asphalt900
  • asphalt900's Avatar
  • Offline
  • Sustaining Member
  • Sustaining Member
    Registered
  • Posts: 1845
  • Thanks: 1259

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

Yesterday 03:48
#926506
Sometimes factory gaskets have a "coating" on them. It's to aid sealing.
The following user(s) said Thank You: Jimbo68

Please Log in or Create an account to join the conversation.

  • Jimbo68
  • Jimbo68's Avatar Topic Author
  • Away
  • User
  • User
    Registered
  • Posts: 123
  • Thanks: 9

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

Yesterday 04:08
#926507
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 😁
 
1981 Kawasaki KZ440-A2

Please Log in or Create an account to join the conversation.

  • Wookie58
  • Wookie58's Avatar
  • Away
  • Moderator
  • Moderator
    Registered
  • Posts: 6648
  • Thanks: 4197

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

Yesterday 04:21
#926508
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)
The following user(s) said Thank You: Jimbo68

Please Log in or Create an account to join the conversation.

  • TexasKZ
  • TexasKZ's Avatar
  • Offline
  • Platinum Member
  • Platinum Member
    Registered
  • Posts: 8324
  • Thanks: 2759

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

Yesterday 05:15
#926509
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.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD slowly moving toward resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/forum/11-projects/620336...amateur-build-thread
The following user(s) said Thank You: Wookie58, Jimbo68

Please Log in or Create an account to join the conversation.

  • Jimbo68
  • Jimbo68's Avatar Topic Author
  • Away
  • User
  • User
    Registered
  • Posts: 123
  • Thanks: 9

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

Today 07:54
#926540
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

Please Log in or Create an account to join the conversation.

  • Jimbo68
  • Jimbo68's Avatar Topic Author
  • Away
  • User
  • User
    Registered
  • Posts: 123
  • Thanks: 9

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

Today 07:55
#926541
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

Please Log in or Create an account to join the conversation.

  • Wookie58
  • Wookie58's Avatar
  • Away
  • Moderator
  • Moderator
    Registered
  • Posts: 6648
  • Thanks: 4197

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

Today 08:01
#926542
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)

Please Log in or Create an account to join the conversation.

Moderators: Street Fighter LTD
Powered by Kunena Forum