In Oct '07 I replaced the Stator and V/R with units from RMSTATOR. Just for reference -Stator -RMG010 @$130.95 and V/R RMR470 @$108.95. Everything was OK until recently. Over the past few days I've been diagnosing a charging issue.. Did the usual systematic procedures and (making a long story short) discovered this, but not after some head-scratching!
A cold solder joint on one of the diodes. The wire simply lifted-off the pin. Not slamming the manufacturer by any means. I've come across this problem with a number of electronic devices, but was able to rectify (no pun intended) the issue by simply re-soldering. Can't do that in this case. The "potting" material probably helped keep the joint secure for continuity but given the heat expansion it finally lost it's conductivity. That's the theory, anyway.
To dig out the potting material I boiled the entire housing for several minutes at a time and picked it out with a small flat screw-driver. Took about 30 minutes, to be able to lift the circuit-board from the heat sink. I went to this trouble because I was at a loss as to what was the true cause of the low charge. Testing the V/R was inconclusive. The Stator checked out, as did the battery.
I've installed a used OEM V/R for now until a new replacement arrives. Something I will point out is regarding the aftermarket V/Rs. Some DO NOT have the BROWN wire ! This is the case with the RM R470 V/R. The schematic for an '80 shows the BROWN wire feeding power to several circuits. This power from this BROWN wire must be redundant and supplied via the circuitry of the two keyed switches. I say this because everything - lights, signals, gauges etc, on this circuit worked with the RM V/R. ???
Something else I discovered. The various prices ????? In my search for a new replacement V/R and in researching 80's era Kawasaki's I found that some use the same wiring color-code - 3 yellows, 1 RED, 1 BLACK and 1 BROWN for the 3 phase systems. Of interest to me was the following:
Kawasaki BJ250 (250TR) 2002-2006
Kawasaki BJ250 (ESTRELLA 250) 1992-2006
Kawasaki KZ1000 (POLICE 1000) 1983-2005
Kawasaki KZ1100 1982-1983
Kawasaki GPZ 1100 (ZX1100A2) 1983-1985
Kawasaki GPZ 750 Turbo (ZX750E2) 1984-1985
Model Number: YHC-091
Price:C $19.90
Free shipping
I'll let y'all know how this works out!