Kawasaki Z200 not charging.

[willingtonste...]

Just acquired a Z200 to renovate. Replaced knackered battery but it won't charge. Checked stator and have a healthy 60v A/C from the single phase alternator @ 40000 rpm. However someone has replaced the Regulator/Rectifier with a 3 phase unit (3 yellow wires and 1 red and 1 black.) I have checked this out and it appears ok but no charge to the battery. The 2 yellow alternator wires get quite hot when connected to 2 of the yellow rectifier leads, could the regulator be knackered ? It's an Electrex RR. Thanks for any idea's.I have a single phase RR off an 300 cc ATV could I use that ?

[Vincent]

Didn't they originally have seperate regulator & rectifier? Or a Diode??
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[pepperami]

Without sounding to obvious ? would`nt it be better just to get the bit`s and return it to original spec?
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[willingtonste...]

Thanks for the answers. These bikes have single phase alternator and single phase 4 wire regulator/rectifiers. I have found a RR for a good price on E-bay so we will see what happens. Thanks again.

[Fizzer Thou]

60vac does sound rather high for a single phase output.This may well be the reason as to why the wires are getting a bit hot as the rectifier/regulator will be struggling to dissipate the heat needed to get the AC volts down to the normal 17vac before it is set as an input to the regulator.

If the existing rectifier/regulator is disconnected from the windings with the engine running,what does it measure across the two output wires? (It will be safe to do this)

While you have your multi-meter handy,check to make sure that the earth points are good.All too often I have found rusty connections where the earth tab or connector should make a clean contact with a bare metal part of the frame or engine.If you happen across such a rusty item,clean it with anything slightly abrasive and smear some grease in place so as to stop any further corrosion in the future.
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[willingtonste...]

Thanks Fizzer, manual says 60V A/C when RR disconnected is good. Yes I thought about the earth connectors but from what I have tested so far all seems good.Stator yellow wires only get hot when connected to RR so I presume Regulator part of RR is duff.