I ordered a new voltage reg/rectifier from Motoparts center for the one that burned up on my Hi Bird 200. They list it as a voltage regulator, not a rectifier. It matches exactly, 4 pin connector plugs right in. The problem is with the new one, every time I try to start the ATV, it blows the fuse. I watched the fuse as I tried to start it & it got red hot & blew. Blew 4 fuses. I disconnected the new reg, put a new fuse in, the ATV started right up & ran fine. My questions are;
Did I get the wrong part?
How do I determine what is the right part?
What does the regulator do if the ATV runs without it?
Thanks for all your help,
Jerry

 

They are both a voltage regulator, making the voltage from the alternator coils peak at under 15 volts and a rectifier, converting the AC current from the alternator to DC for the battery. I would suspect you have got a new dud voltage regulator but you could have connected it wrongly as Chinese wiring colours vary and so do plugs and sockets, yellow is normally the wire colour for alternator wires and red for battery positive but you can't guarantee this on Chinese machines. Without the regulator the battery won't charge and you may get high voltages fed through the CDI, blowing it as well.

 

The regulator I got is a 4 pin just like the burned up one. It plugs into my harness only 1 way & clips on. I can't plug it in any other way.

 

Honda made four different CDIs for the 300 Big Red, all had the same type of plugs and sockets but were incompatible with one another. Just because it plugs in doesn't mean it was made for your machine, check those wire colours, if they match you could have a new dud regulator.

 

I looked at my old regulator & realized the new one was wired wrong. I pulled the pins out of the plug on the new one & put them back in so the wire colors matched my wiring harness. That did the trick, seems to be working just fine. Thanks so much for your help.