I have a 2002 polaris and i just bought a voltage regulator on ebay and i ordered a 400 and they sent me a 500 instead and they wont take it back. My 2002 400 has 5 wires a red ,yellow. yellow with brown strip and yelloe with red strip and a brown. The 500 has just a red.yellow...yellow with red strip and brown. My question is can i make this 500 one work??Its missing the yellow with brown strip wire. Didnt no if i can put 2 wires together on my old one.

 

Don't think you can since you have a 5 wire system. If they wont take it back even in the original package you can try this place.Look at the # on the side or back of your old regulator and match it up.Polaris ATV Rectifier Regulator Shows to be a 4060191 if it's a 400 4 stroke,BUT it's been updated on this site,but you could still use the old part # replacement at a much cheaper price..http://www.cyclepartswarehouse.com/f...2002&fveh=5583 Hope I haven't confused you or myself!

 

is there anyway to test it once i have it off....so i dont have to waste the money again

 

Should be a small amount of resistance between each stator yellow wire to another leading to the regulator and no yellow should short to ground. This eliminates the stator as the problem on charging. If this checks out ok,manual says to replace the regulator/rectifier.

 

so can i test this off the machine?..

 

No test on the regulator,just the stator wires leading to it. Manual says once the stator,battery,connections have been eliminated,replace the regulator. Doesn't show any test such as wire to wire on the regulator,etc. Some I've found that you could tell the regulator was bad by the burnt smell or melted or bulged cases.

 

yup i just noticed a little bulged in the case by the yellow and brown wire...the case has spider like cracks where it is bulged

 

Bingo.... Plus I'd call when you order another one to make sure!

 

thank you very much sir

 

Sorry,but I couldn't resist! This movie just came to mind