Charging System Testing Flow Chart - Polaris Ranger RZR SW Service 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 exposed 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
engine and increase RPM to between 3000
and 4000. Read battery voltage with the
multitester. Readings should increase to
between 13.0 and 14.6 V D.C. Do they?
No
Meter Setting: DC Amps
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 multitester, perform an Alternator
Output test. See test procedure on Page 10.24.
Does output meet specification?
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 voltage present?
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 voltage regulator.
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
No
or a fully charged shop battery.
Yes
Check Key off Current Draw.
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 between
the panel and the stator for
damage. If no damage is found,
remove the recoil and flywheel.
No
Inspect the flywheel magnets, stator
coils and stator wires for damage.
Repair or replace any damaged
components.
Check stator, regulator, ground, battery
and battery connections. Also check
No
wire connections and wire condition.
Repair or replace faulty wiring or
components.
ELECTRICAL
10
10.25