ELECTRICAL
Charging System
Charging System Testing
Whenever charging system problems are suspected, proceed with the following system check.
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (See
page 10.22). It should be 12.4 volts or
more. Is it?
Yes
,
Meter Setting: DC Volts
With the transmission in neutral, start the
engine and increase RPM to between 3000
and 4000. Read battery voltage with the
multitester. Readings should be between
13.0 and 14.6 V D.C.
Are thev?
No
,
Meter Setting: DC Amps
Perform system "Break Even Amperage"
test outlined on page 10.25.
Does charging occur as specified?
No
Meter Setting: AC Amps
Disconnect the Yellow/Red, Yellow, and Yel-
low/Brn (if applicable) wires from the regula-
tor/rectifier. Using a multitester, perform an
Alternator Output (AC amp) test. See test
procedure on page 10.25 for procedure.
Is output above 5 amps?
Yes
Meter Setting: DC Volts
Reconnect the alternator wires. Note: Red
wire must be connected to harness. Battery
voltage must be present on red wire terminal
on harness side of voltage regulator connector.
Is it?
Yes
,
If all of the previous tests indicate a
good condition, but the charging voltage
does not rise above battery voltage at the
connector or terminal board, replace the
voltage regulator.
12/97
Remove the battery and properly ser-
............. No ____ vice. Reinstall the fully charged battery
or a fully charged shop battery.
...--.. ::. .... Yes
--....J
Check Key off Current Draw
No
--II-
10.24
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
below the "Break Even" RPM. Con-
tinued problems would call for battery
inspection.
Inspect the wiring harness be-
tween the panel and the stator for
damage. If no damage is found,
remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
tor coils and stator wire harness
for damage. Repair or replace
any damaged components.
Check regulator/rectifier connections
and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
Polaris Industries Inc.