Charging System "Break Even" Test; Alternator Tests (Charging System) - Polaris Outlaw 500 Service Manual

Charging System "Break Even" Test

CAUTION
Do not allow the battery cables to become
disconnected with the engine running.
Follow the steps below as outlined to reduce
the chance of damage to electrical
The "break even" point of the charging system is the point at
which the alternator overcomes all system loads (lights, etc.)
and begins to charge the battery. Depending on battery condition
and system load, the break even point may vary slightly. The
battery should be fully charged before performing this test.
WARNING
Never start the engine with an ammeter
connected in series. Damage to the meter or
meter fuse will result. Do not run test for
extended period of time. Do not run test with
1. Connect a tachometer to the engine.
2. Using an inductive amperage metering device, (set to DC
amps) connect to the negative battery cable.
3. With engine off and the key, kill switch, and lights in the
"ON" position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive reading
is indicated.
4. Shift transmission into Park and start the engine. With the
engine running at idle, observe meter readings.
5. Increase engine RPM while observing ammeter and
tachometer.
6. Note RPM at which the battery starts to charge (ammeter
indication is positive).
7. With lights and other electrical loads off, the "break even"
point should occur at approximately 1500 RPM or lower.
8. With the engine running, turn the lights on and engage
parking brake lock to keep brake light on.
9. Repeat test, observing ammeter and tachometer. With
lights on, charging should occur at or below 2000 RPM.

Alternator Tests (Charging System)

Three tests can be performed using a multimeter to determine
the condition of the stator (alternator).
TEST 1: Resistance Value of Each Stator Leg
1. Measure the resistance value of each of the three stator
legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3. Each should
measure 0.49 ohms.
NOTE: If there are any significant variations in ohms
readings between the three legs; it is an indication
that one of the three stator legs may be weak or
failed.
TEST 2: Resistance Value of Stator Leg to Ground
1. Measure the resistance value of each of the stator legs to
ground: Y1 to Ground, Y2 to Ground, Y3 to Ground.
NOTE: Any measurement other than Infinity (open)
will indicate a failed or shorted stator leg.
TEST 3: Measure AC Voltage Output of Each Stator
Leg at Charging RPM with a Voltmeter set to Volts AC.
1. Set the voltmeter to read AC Voltage.
2. Start the engine and let it idle.
3. Separately test each 'leg' of the stator by connecting the
meter leads to the wires leading from the alternator (Y1 to
Y2, Y1 to Y3, Y2 to Y3). Alternator Output Readings
should be no less than 30-40V AC above 2000 RPM on
each 'leg'.
NOTE: If stator leg AC output varies significantly
from the specified value, the stator may need to be
replaced.
ELECTRICAL
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