Charging System Testing - Polaris General 2020 Service Manual

CHASSIS / BODY ELECTRICAL

CHARGING SYSTEM TESTING

Whenever charging system problems are suspected, proceed with the following system check after verifying that all
wires are in good condition, connected and not exposed or pinched.
Using a multitester, set on D.C. volts, measure the
battery open circuit voltage (test with lights and
accessories off). It should be 12.4 volts or more.
Is it?
↓
Yes
Meter Setting: DC Volts
With the transmission in park, start the engine and
increase the RPM to between 3000 and 4000.
Read the battery voltage with the multimeter.
Readings should start to increase between 13.0 V
D.C. and 14.6 V D.C. Do they?
NOTE: Disconnect all accessories.
↓
No
Meter Setting: DC Volts
Perform system Break Even Amperage test
outlined in this chapter. Does charging occur as
specified?
↓
No
Ohm stator wires, if bad replace stator, if good,
continue with alternator output test.
Meter Setting: AC Volts
Disconnect the Yellow wires from the regulator /
rectifier. Using a multimeter, perform an
Alternator Output Test. See the test procedure
detailed in this chapter. Does output meet
specification?
↓
Yes
Meter Setting: DC Volts
Reconnect the alternator wires. Measure between
the Red and Black terminals with the harness
disconnected. Battery voltage must be present on
on harness side of voltage regulator connector. Is
voltage present?
↓
Yes
If all the previous tests indicate a good condition,
but the charging voltage does not rise above
battery voltage at the connector or wire harness,
replace the voltage regulator.
12.58
→
Remove the battery and properly service.
Reinstall the fully charged battery or fully charged
No
→
Yes
→
Check for owner modification, and discuss
operating habits. The battery will continually
discharge if operated below the "Break Even"
RPM. Continued problems would call for battery
Yes
→
Inspect the wiring harness between the regulator
and the stator for damage. If no damage is found,
remove the stator cover. Inspect the flywheel
magnets, stator coils, and stator wires for
No
damage. Repair or replace any damaged
→
Check battery and battery connections. Also
check wire connections and wire condition. Repair
or replace faulty wiring or components.
No
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
shop battery.
Check Key off current draw.
inspection.
components.
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