We all went our for a few hours this weekend and on the way back we noticed that the tail light on my brother's 400 explorer, was very dim. When we got to the house, it wouldn't crank with the starter, so I checked the battery voltage and found it to be just over 9 volts static. I then pull started it and checked the voltage with the engine running at 3000 rpm's and it stayed at just over 9 volts; I also should mention that the battery is less than a week old and the cables are good.

I checked all the connections and grounds and found them to all be good; I then checked for battery voltage at the red wire on the voltage regulator and it did have battery voltage at the regulator/rectifier, so we have continuity between the battery and regulator/rectifier. I guess I'll have him go get a new voltage regulator/rectifier, but I'd like to pick you guy's brains and see if there isn't something else I'm missing before digging in his wallet. Thanks in advance.....

 

SOUNDS like you found the problem! If has power in on the red wire,but not charging its the reg/rectifier, IF all other wires are plugged in and have good contact. OPT

 

Thanks OPT, I was hoping I hadn't missed anything.

 

the only oops I have had with this sort of thing. Is putting a four magnet flywheel on a bike that needs a six magnet one. you can check for voltage going into the regulator. I think i had 16-18 volts something like that.

 

Yes, I have read where some folks have done that; this one has the stock flywheel on it.

 

I have an 1999 Xplorer 400. I tried to use a 4 magnet flywheel. It would not charge the system with a 4 magnet flywheel. As soon as I switched it back to a 6 magnet flywheel the system worked fine. Hope this helps.

 

Update: I finally found the time to put a new rectifier/regulator in and the ATV charges like new! Thanks for allowing me to pick your brains.

 

Glad you got it fixed, now go ride it! OPT