Im working on a 08 ranger 500 that's not charging, I checked the stator and it was jumping around on voltage output and low intermittent so I replaced it with a new on , now I have consistant voltage on all three legs but its about 60 percent low on all three legs at idle it 6.5 ac and at 3000 rpm its 16.0 ac I can only get 12.9 volts max at battery. I checked ohms to ground all three legs open I checked leg to leg all within spec per manual I pulled stator out and took it to a alternator shop he said same as I it all looks good of course they cant spin check it for ac output. and I am checking it at stator not at or after rectifier regulator. Its either a bad stator out of the box or is it possible the flywheel is not magnetized enough went bad??? any help or ideas?? I have another stator on the way my luck is that it will do the same thing

 

You don't say if it's the carb model or efi,but 9 out 10 times it's the ecm(regulator) that shorts out. Carb model item#1. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Efi model regulator item#1.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

It's efi I know of the regulator issue but I'm checking out put before regulator with it unplugged so how is that the problem

 

You've had two stators including the original and waiting on the third from what I'm understanding. Resistance tests and even ac tests may not be 100% accurate. Can't even remember ever having to replace a Ranger stator on charging issues even though on electrical problems anythings possible.Replaced a lot of ecms and regulators though and this model did have a problem on the regulator as you can see by the updated part number. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

ok Ill give it a shot if it fixes it ill be happy but still don't understand unless its pulling or grounding out on the pickup side since that's the only thing pluged in while running, as always I really appreciate the advice opt. your and asset to this board!!!

 

opt, I put 3 rd stator in and still same problem not putting out enough ac volts, so I just put in a new Polaris regulator and still no change in anything, ac output per leg is 7.9 I checked it at stator and at top right before regulator , I cant figure it out , all stators ohm out right, and not grounding on any leg they just wont put out enough , the only thing I haven't tried Is replacing the fly wheel, I have another flywheel from a newer 500 laying around and its a lot thicker and has a lot more magnetism to it any thoughts?

 

After 3 stators and if you have a new regulator and still not charging 14-14.5 volts back to the battery,I wouldn't throw any more parts at it! Time to have it put on Digital Wrench to help find the problem. Could even be a problem with the ecu/brain module. Only so much you can do on efi machines at home..

 

You changed the stator , resistance checks are ok , and voltage is still low from the stator leads { you did have your meter on AC ? } then the only other thing it could be is the flywheel magnets are weak , you should have well in excess of 14 volts AC on the stator leads . Change the flywheel and you'll be in the right direction .

 

yooper thanks for the response that's the only thing I think it can be I ordered the flywheel should be here this week,I have another 500 flywheel lying around (newer one wont fit this on unless change backing plate) but on the bench I can drop stator in and it snaps in with force, on the bad one I drop it in and it floats in there so I think that's it, and yes I am checking ac volts they are half of what they should be, I thought maybe there going in to ground but ive checked it several times and all the stators check out fine ,I even took them to a good alternator shop he said they ohm and ground fine. Ill let yall know what I find

 

just wanted to say the flywheel was the problem I put the new one in and now have 14.5 volts to battery, and I checked the magnetism difference between the two it was night and day different almost like the polarity changed in some of the magnets, anyway its fixed thanks guys.