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Help Alternator/Regulator issue - A model

Discussion in 'Kawasaki 250cc In-line 4's' started by Adam Giles, Mar 28, 2017.

  1. Adam Giles

    Adam Giles Well-Known Member

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    My Bike:
    zxr250 1989 + 1993
    So my girlfriends A-model was having intermittent flat battery issues, but seemed to run great once started.
    Battery checked out fine.
    So today I decided to open her up and check Alternator and Reg/Rec.
    Started by checking the output voltage at battery. All looked good (14 - 15 volts) when running. Tried with high beam on and it dropped quite a bit.
    Pulled the tank off to check Alternator output voltage and when I disconnected Regulator, I found this...
    7246843df6d9ff33f5a1b6093d925b6b.jpg
    It's the Y3 wire which is all burnt out.
    Did the test anyway and got a good voltage reading on all three cables.
    So Alternator should be good. But what would cause this? Dodgy Regulator? (I don't have 3 batteries available to test it) Or maybe just a lose connection?

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  2. 2valve

    2valve Well-Known Member

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    To me , it looks like a bad connection that's done all of that damage. I'd personally would be cutting the loom back until you find good clean wires , make another small loom so it's still the correct length again and fit new terminals and especially another connection plug , don't forget to check the other connection plug for damage.And give it a test. Beware of the cheap terminals on the market these days , there real soft and don't hold together well causing hot spot's.
     
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  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    My Bike:
    *Kawasaki ZXR250C *Yamaha FZR250R 3LN1 *Yamaha FZR400 *Triumph Bonneville 750 T140V *Triumph Daytona 675 *Triumph Tiger 800XC
    The C model RRs are known to heat up to the extreme due to the bad positioning so Id assume the A isnt much better

    Yours looks pretty dirty as well so I would clean it up so the fins can do their job better at cooling

    Check the airflow to the RR is not impeded by anything

    Test it also to see it hasnt cooked itself

    C model test

    rr test.png
     
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  4. Adam Giles

    Adam Giles Well-Known Member

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    Built a mini loom with new connector. Plugged it up but it was putting out about 16.5v. Replaced reg/rec with a new one and it's sitting solid at 15v.

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