How to Replace Kawasaki Voltage Regulators

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Your Kawasaki motorcycle, ATV, jet ski, tractor or mower has a voltage regulator that provides a consistent level of electrical current in the electrical system. Even though voltage regulators and wiring vary with a particular machine, the wire codes provided with a new regulator are used to make the correct connections when installing the unit. Obtain a replacement voltage regulator by referring to the year and model of your machine, or by using the part number on the existing regulator. You replace a Kawasaki voltage regulator with the machine parked and the engine completely cool.

Things You'll Need

  • Service manual for your machine (if available)
  • Replacement voltage regulator
  • Miscellaneous hand tools
  • Disconnect the positive battery cable from the battery. Skip this step if your machine has a pull-starter.

  • Locate the voltage regulator by looking at the electrical system diagram in your service manual. If necessary, follow the procedures in your manual and remove the rider’s seat, engine cover or fairing to identify and access the voltage regulator.

  • Hold the new regulator close the existing regulator. Establish the correct way to mount the new regulator so the wires and wire connectors are facing the same way.

  • Verify the colors of each wire on the old and new regulator and note the connections for each wire on your machine. Read the instructions that came with the new regulator to verify the wire colors.

  • Detach the existing regulator wires where they connect to a wire connector or electrical post on the machine. Typically, plastic connectors are detached by pressing a raised tab on one side of the connector as you pull the male and female connectors apart. Wire connectors that attach to an electrical post are removed using a screwdriver. Save these screws.

  • Loosen and remove the screws or small bolts that hold the regulator in place and save these. Remove and discard the old regulator.

  • Install the new regulator onto the machine using the saved screws or bolts and tighten each securely.

  • Attach each wire from the new regulator to the appropriate plastic connector by pushing the corresponding male and female connectors together until the tab snaps up. Attach each wire to the appropriate electrical post using the saved screws.

  • Reattach the removed rider’s seat, engine cover or fairing onto the machine. Reconnect the positive battery cable to the battery.

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