Charging System Testing Flow Chart - Polaris Outlaw 500 Service Manual

ELECTRICAL

Charging System Testing Flow Chart

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 7.12). It should be 12.5 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 increase to be-
tween 13.0 and 14.6 V D.C. Are they?
No
Meter Setting: DC Amps
Perform system "Break Even Amperage"
test outlined on Page 7.13.
Does charging occur as specified?
Ohm stator (Y) wires. If failed, replace, if good,
continue with alternator output test.
Meter Setting: AC Volts
Disconnect the Yellow wires from the regu-
lator/rectifier. Using a multitester, perform
an Alternator Output Test. See
test procedure on Page 7.13 for procedure.
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.
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.
7.14
No
Is it?
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,
remove the recoil and flywheel.
No
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-
No
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
RepairPro Service Manual