Charging System Testing Flow Chart - Polaris 2005 SPORTSMAN 500 Servise Manual

CHARGING SYSTEM TESTING FLOW CHART

Whenever charging system problems are suspected, proceed with the following system check after verifying that
all wires are in good condition, connected and not kinked or pinched.
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (See
earlier test). It should be 12.4 volts or
more. Is it?
Yes
Meter Setting: DC Volts
With the transmission in Park, start the en-
gine and increase RPM to between 3000 and
4000. Read battery voltage with the multi-
tester. Readings should increase to between
13.0 and 14.6 V D.C. Are they?
No
Meter Setting: DC Amps
Perform system "Break Even Amperage"
test outlined on Page 10.21.
Does charging occur as specified?
No
Ohm stator wires If bad, replace stator. If good,
continue with alternator output test.
Meter Setting: AC Amps
Disconnect the wires from the regulator/rec-
tifier. Using a multitester, perform an Alter-
nator Output (AC amp) test. See test pro-
cedure on Page 10.21 for procedure.
Is output above 7 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 wire harness, replace the volt-
age regulator.
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
No
or a fully charged shop battery.
Check Key off Current Draw
Yes
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
Yes
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,
No
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
No and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
ELECTRICAL
10.23