Charging System Testing Flow Chart - Polaris 2007 SPORTSMAN X2 800 Service Manual

ELECTRICAL

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, measure 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 and 14.6 VDC.
Are they?
No
Meter Setting DC Amps
Perform system Break Even Amperage Test"
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/rectifier.
Using a multitester, perform an Alternator Output
(AC amp) test. See test procedure on Page 10.20
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 voltage regulator.
10.24
Remove the battery and properly service.
Reinstall the fully charged battery or a fully
No
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"
Continued 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
No
flywheel. Inspect the flywheel magnets,
stator coils and stator wire harness for
damage. Repair or replace any damaged
components.
Check regulator/rectifier connections and
ground, battery connections, circuit
No
breaker and connecting wires. Repair or
replace faulty wiring or components.
RPM.