Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 257 / 289

ELECTRICAL
10.29
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.
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.
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 10.31 for procedure.
Is output above 7 amps?
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.
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?
Check regulator/rectifier connections
and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
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.
No
Yes
No
Yes
Perform system “Break Even Amperage”
test outlined on 10.31.
Does charging occur as specified?
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?
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
or a fully charged shop battery.
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
Yes
No
Yes
Check Key off Current Draw
No
Meter Setting: AC Amps
Meter Setting: DC Amps
Meter Setting: DC Volts
Meter Setting: DC Volts
Yes
Ohm stator wires. If bad, replace stator. If
good, continue with alternator output test.