Alternator Cover Removal
- Remove the lower fairing (See Lower Fairing Removal in the Frame chapter).
- Disconnect the alternator lead connector [A].
![](https://motoinstruction.ru/img/kawasaki/23/129123.jpg)
- Place a suitable container under the alternator cover [A].
Remove:
- Alternator Cover Bolts [B]
- Clamp [C]
- Bracket [D]
Pull the alternator cover outside.
![](https://motoinstruction.ru/img/kawasaki/23/129124.jpg)
Alternator Cover Installation
- Apply silicone sealant to the alternator lead grommet and crankcase halves mating surface [A] on the front and rear sides of the cover mount.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
- Check that dowel pins [B] are in place on the crankcase.
- Install a new gasket and the alternator cover.
Tighten:
Torque - Alternator Cover Bolts: 9.8 Nm (1.0 kgf·m, 87 in·lb)
![](https://motoinstruction.ru/img/kawasaki/23/129125.jpg)
Stator Coil Removal
Remove:
- Alternator Cover (See Alternator Cover Removal) Holding Plate Bolt [A] and Plate
- Alternator Lead Grommet [B]
- Stator Coil Bolts [C]
- Remove the stator coil [D] from the alternator cover.
![](https://motoinstruction.ru/img/kawasaki/23/129126.jpg)
Stator Coil Installation
- Apply a non-permanent locking agent to the threads of the stator coil bolts and tighten them.
Torque - Stator Coil Bolts: 12 Nm (1.2 kgf·m, 106 in·lb)
- Secure the alternator lead with a holding plate, and tighten the bolt.
Apply a non-permanent locking agent to the threads of the holding plate bolt.
Torque - Alternator Lead Holding Plate Bolt: 9.8 Nm (1.0 kgf·m 87 in·lb)
- Apply silicone sealant to the circumference of the alternator lead grommet, and fit the grommet into the notch of the cover securely.
Sealant - Kawasaki Bond (Silicone Sealant): 92104-0004
- Install the alternator cover (See Alternator Cover Installation).
Alternator Rotor Removal
Remove:
- Alternator Cover (See Alternator Cover Removal)
- Shafts [A]
- Starter Idle Gear [B]
- Torque Limiter [C]
![](https://motoinstruction.ru/img/kawasaki/23/129127.jpg)
- Wipe oil off the outer circumference of the rotor.
- Hold the alternator rotor steady with the rotor holder [A], and remove the rotor bolt [B] and washer.
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1658
![](https://motoinstruction.ru/img/kawasaki/23/129128.jpg)
- Using the flywheel puller [A], remove the alternator rotor from the crankshaft.
Special Tool - Flywheel Puller Assembly, M38 x 1.5/M35 x 1.5: 57001-1405
Caution: Do not attempt to strike the alternator rotor itself. Striking the rotor can cause the magnets to lose their magnetism.
![](https://motoinstruction.ru/img/kawasaki/23/129129.jpg)
Alternator Rotor Installation
- Using a cleaning fluid, clean off any oil or dirt on the following portions and dry them with a clean cloth.
- Crankshaft Tapered Portion [A]
- Alternator Rotor Tapered Portion [B]
- Apply a thin coat of molybdenum disulfide grease [C] to the crankshaft.
![](https://motoinstruction.ru/img/kawasaki/23/129130.jpg)
- Install the starter motor clutch gear [A] and washer [B].
- Again, clean the crankshaft tapered portion [C] and dry there.
![](https://motoinstruction.ru/img/kawasaki/23/129131.jpg)
- Install the alternator rotor [A] while turning [B] it counterclockwise.
![](https://motoinstruction.ru/img/kawasaki/23/129132.jpg)
- Install the washer [A].
Note: Confirm the alternator rotor fit or not to the crankshaft before tightening it with specified torque.
- Apply molybdenum disulfide oil solution to the threads and seating surface of the rotor bolt.
- Install the rotor bolt [B] and tighten it with 70 Nm (7.0 kgf·m, 52 ft·lb) of torque.
Remove the rotor bolt and washer.
![](https://motoinstruction.ru/img/kawasaki/23/129133.jpg)
- Check the tightening torque with flywheel puller [A].
If the rotor is not pulled out with 20 Nm (2.0 kgf·m, 15 ft·lb) of drawing torque, it is installed correctly.
If the rotor is pulled out with under 20 Nm (2.0 kgf·m, 15 fflb) of drawing torque, clean off any oil dirt or flaw of the crankshaft and rotor tapered portion, and dry them with a clean cloth. Then, confirm that it is not pulled out with above torque.
![](https://motoinstruction.ru/img/kawasaki/23/129134.jpg)
Install the rotor bolt and washer.
Tighten the alternator rotor bolt [A] while holding the alternator rotor steady with the rotor holder [B].
Special Tools - Grip: 57001-1591
Rotor Holder: 57001-1658
Torque - Alternator Rotor Bolt: 155 Nm (15.8 kgf·m, 114 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/129135.jpg)
Apply a thin coat of molybdenum disulfide grease to the shafts [A], and install them.
Install the torque limiter [B] and starter idle gear [C].
Install the alternator cover (See Alternator Cover Installation).
![](https://motoinstruction.ru/img/kawasaki/23/129136.jpg)
Alternator Inspection
There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism. A short or open in one of the coil wires will result in either a low output, or no output at all. A loss in rotor magnetism, which may be caused by dropping or hitting the alternator, by leaving it near an electromagnetic field, or just by aging, will result in low output.
- To check the alternator output voltage, do the following procedures.
Turn off the ignition switch.
Disconnect the alternator lead connector [A].
Connect the hand tester as shown in the table 1.
Start the engine.
Run it at the rpm given in the table 1.
Note the voltage readings (total 3 measurements).
![](https://motoinstruction.ru/img/kawasaki/23/129137.jpg)
Table 1 Alternator Output Voltage
Tester Range | Connections | Reading at 4 000 rpm | |
Tester (+) to | Tester (-) to | ||
AC 250 V | One White lead | Another White lead | 42 V or more |
If the output voltage shows the value in the table, the alternator operates properly.
If the output voltage shows a much higher than the value in the table, the regulator/rectifier is damaged. A much lower reading than that given in the table indicates that the alternator is defective.
- Check the stator coil resistance as follows.
Stop the engine.
Connect the hand tester as shown in the table 2.
Note the readings (total 3 measurement).
Table 2 Stator Coil Resistance
Tester Range | Connections | Reading | |
Tester (+) to | Tester (-) to | ||
x 1 Ω | One White lead | Another White lead | 0.18-0.27 Ω |
If there is more resistance than shown in the table, or no hand tester reading (infinity) for any two leads, the stator has an open lead and must be replaced. Much less than this resistance means the stator is shorted, and must be replaced.
- Using the highest resistance range of the hand tester, measure the resistance between each of the black leads and chassis ground.
Any hand tester reading less than infinity (~) indicates a short, necessitating stator replacement.
If the stator coils have normal resistance, but the voltage check showed the alternator to be defective; then the rotor magnets have probably weakened, and the rotor must be replaced.
Special Tool - Hand Tester: 57001-1394
Regulator/Rectifier Inspection
KLE650A Models
Remove:
- Left Rear Frame Cover (See Rear Frame Cover Removal in the Frame chapter)
- Bolts [A]
![](https://motoinstruction.ru/img/kawasaki/23/129138.jpg)
- Disconnect the connector [A].
![](https://motoinstruction.ru/img/kawasaki/23/129139.jpg)
Remove:
- Bolts [A]
- Regulator/Rectifier [B]
![](https://motoinstruction.ru/img/kawasaki/23/129140.jpg)
KLE650B Models
Remove:
- Muffler Body (See Muffler Body Removal in the Engine Top End chapter)
- Bolts [A]
![](https://motoinstruction.ru/img/kawasaki/23/129141.jpg)
- Disconnect the connector [A].
- Remove the regulator/rectifier [B].
![](https://motoinstruction.ru/img/kawasaki/23/129142.jpg)
Rectifier Circuit Check
- Check conductivity of the following pair of terminals.
Rectifier Circuit Inspection
Tester connection | W/BL-BK1 | W/BL-BK2 | W/BL-BK3 |
BK/Y-BK1 | BK/Y-BK2 | BK/Y-BK3 |
![](https://motoinstruction.ru/img/kawasaki/23/129143.jpg)
The resistance should be low in one direction and more than ten times as much in the other direction. If any two leads are low or high in both directions, the rectifier is defective and the regulator/rectifier must be replaced.
Note: The actual meter reading varies with the meter used and the individual rectifier, but, generally speaking the lower reading should be from zero to one half the scale.
Regulator Circuit Check
To test the regulator out of circuit, use three 12 V batteries and a test light (12 V 3-6 W bulb in a socket with leads).
Caution: The test light works as an indicator and also a current limiterto protect the regulator/rectifierfrom excessive current. Do not use an ammeter instead of a test light.
- Check to be sure the rectifier circuit is normal before continuing.
- Do the 1st step regulator circuit test.
Connect the test light and the 12 V battery to the regula-tor/rectifier as shown.
Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective. Replace it.
If the test light does not turn on, continue the test.
![](https://motoinstruction.ru/img/kawasaki/23/129144.jpg)
- Do the 2nd step regulator circuit test.
Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step".
Apply 12 V to the voltage BR terminal.
Check the BK1, BK2 and BK3 terminal respectively.
If the test light turns on, the regulator/rectifier is defective. Replace it.
If the test light does not turn on, continue the test.
![](https://motoinstruction.ru/img/kawasaki/23/129145.jpg)
- Do the 3rd step regulator circuit test.
Connect the test light and the 12 V battery in the same manner as specified in the "Regulator Circuit Test-1st Step".
Momentarily apply 24 V to the voltage BR terminal by adding a 12 V battery.
Check the BK1, BK2 and BK3 terminals respectively.
Caution: Do not apply more than 24 V. If more than 24 V is applied, the regulator/rectifier may be damaged. Do not apply 24 V more than a few seconds. If 24 V is applied for more than a few seconds, the regulator/rectifier may be damaged.
![](https://motoinstruction.ru/img/kawasaki/23/129146.jpg)
If the test light did not light when the 24 V was applied momentarily to the voltage monitoring terminal, the regu-lator/rectifier is defective. Replace it.
If the regulator/rectifier passes all of the tests described, it may still be defective. If the charging system still does not work properly after checking all of the components and the battery, test the regulator/rectifier by replacing it with a known good unit.
Charging Voltage Inspection
- Check the battery condition (See Charging Condition Inspection).
- Warm up the engine to obtain actual alternator operating conditions.
- Remove the seat (See Seat Removal in the Frame chapter).
- Check that the ignition switch is turned off, and connect the hand tester [A] to the battery terminals [B].
Special Tool - Hand Tester: 57001-1394
- Start the engine, and note the voltage readings at various engine speeds with the headlight turned on and then turned off (To turn off the headlight, disconnect the headlight connector on the headlight unit.). The readings should show nearly battery voltage when the engine speed is low, and, as the engine speed rises, the readings should also rise. But they must be kept under the specified voltage.
![](https://motoinstruction.ru/img/kawasaki/23/129147.jpg)
Charging Voltage
Tester Range | Connections | Reading | |
Tester (+) to | Tester (-) to | ||
DC 25 V | Battery (+) | Battery (-) | 14.2-15.2 V |
- Turn off the ignition switch to stop the engine, and disconnect the hand tester.
If the charging voltage is kept between the values given in the table, the charging system is considered to be working normally.
If the charging voltage is much higher than the values specified in the table, the regulator/rectifier is defective or the regulator/rectifier leads are loose or open.
If the charging voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternator output is insufficient for the loads. Check the alternator and regulator/rectifier to determine which part is defective.
Charging System Circuit
![](https://motoinstruction.ru/img/kawasaki/23/129148.jpg)
1. Ignition Switch; 2. Alternator; 3. Regulator/Rectifier; 4. Water-proof Joint C; 5. Main Fuse 30 A; 6. Battery 12 V 10 Ah; 7. Load