04 500 HO. While riding the battery light came on flashing. The headlights were on and the light would flash when the fan came on and it would stop if I turned the lights off. I replaced the battery due to it being about 3 years old. The charging rate is about 12.5-13.1 volts I think it's a little low. When this was new I had a problem under the front cowl some wires on the regulator were pulled tight and I moved them so they had slack. So I guess my question is do you think it might be the regulator or the stator?
Thanx!

 

the 12 to 13 volts is normal at idle. after about 1/4 throttle it should jump up to about 14.5 to 15.5 volts

 

Thats all it's putting out at about 4500-5000 rpms.

 

check to make sure there isnt any rust on the flywheel magnets. take some fine emory cloth and sand the magnets and the stator windings lightly to remove any rust. dont want to do it to much because it would change the spacing and reduce the output even more.

 

Think I got it. I pulled the front cover and found the voltage regulator was hot when running I removed the screws and pulled it out and found a hole burned threw the housing after moving the wires it would jump up to 14.5 volts and then back down to 12.4 volt so I ordered a new regulator (BIG $$$$$$$$$$) and will put it back in when I get it.

 

Twister,
What does the voltage regulator look like? what is it mounted near? How is it identified.
Is there a part number on it?
Thanks, for future reference.
Deerkiller

 

It's mounted on a cross bar in front of the radiator. You need to remove the front rack and cowl/cover and it's black with a silver mounting bracket held in with two torx screws. Mine has 4 wires red, black, yellow, and yellow with a red stripe.

 

I think Polaris uses the term "Controller Module" there about $115!

http://216.37.204.206/wps/Pola...asp?Type=13&A=341&B=17

#29 I think.

 

I got mine from cheap cycle dot com $90.24 with shipping all of the dealers around me were $ 109.00-124.00 no discount even from the dealer I got three machines from. It's still alot of money but it pays to look around.

 

If it's the same as an ECM I had to change one too. Some had a recall, Mine was not included. There are a lot of different problems caused by the bad one's. I paid $125.00.
Deerkiller