I have a 2004 Sportsman 600 that seems to be a rare build (5/17/2004).
I have determined that the voltage regulator needs to be replaced because the speedometer was displaying the battery symbol and when I put a volt meter on the battery, I can see that the voltage is getting up to 20 volts when I rev the engine.The part number is 4011053 and it has seven wires.
Does anyone know where I might get one for a reasonable price? (I'm in Canada)
As another option, does anyone know what might be so special about this voltage regulator versus the other sportsman 600s (p/n 4010796 and 4010929). I am guessing that it is just a matter of either the input from the stator is different for my model or that the output capacity is different for my model (perhaps it needs to handle more power) ?
Asked another way... Is there any other voltage regulator that would work on my bike?

 

Did you ever figure anything out? I'm having the same issue.
Thanks

 

Yes. I bought one for a 700 or 800 and changed the wiring to match. I will see if I have a picture of it and/or if I have the part number for the one I bought.
The one I got was quite a bit larger with a large heat sink and that is a good thing but I did have to create a new mounting bracket to fit it under the hood.


This may or may not give you enough information to order one. I will see if I can find more info.

Here is the old versus the new one. I cut the connectors for the yellow wires off the old one to splice onto the new one. I can't remember if the red and black connector was OK as it was or if I had to switch any wires.

Here is how I mounted the new (larger) one. I just used a piece of aluminum I had laying around.

 

The part description was as follows. It is still available on Amazon.

Li Bai Mosfet Voltage Regulator Rectifier For Polaris Ranger 500/700 RZR 800 Sportsman 500/700 / 800 2007 2008 2009 2010 OEM Repl.# 4011569 4012384 4011925

 

By the way, I have also posted more information and pictures in another reply but that reply is waiting for moderation.

 

Hi Warrior,

Sorry for reopening an old thread but it appears we are in the minority of late model 2004. I am following your plan but my question is what did you do with the 8th wire? I can see it in this photo but thinking you just didn't connect it.

I have the 2004 Sportsman 700 Twin with the manufacture date of 17 May 2004 which has the same un-finned VR that you have.

It has been quite some time since I posted as I have has no issues for some time then this issue popped up and Partzilla as the replacement VR for $425 and do not really want to go that route as it was poor design for thermal capacity.

Thanks in advance!

Craig

 

I can't access the bike at the moment but I am pretty sure that I just used the 3 yellow wires from the new regulator and then just taped up that yellow wire with the red stripe.
Note that it does not matter which of the 3 yellow wires go to which wires from the stator. It is a 3-phase stator.
One other thing that I recall is that I tried to measure the 12v voltage from the regulator without hooking it up to the battery but that did not work. That is because the regulator has some protection circuitry that shuts it off if it does not detect 12v across the red and black wires. Once I hooked up the battery I could see that it was charging (again, I can't remember the voltage but it was at least 14v).

 

I have one yellow and two yellow w/red tracer.
The new part has three yellow and one yellow w/red tracer. Do I hook all three yellow together and connect the one tracer together?
The red and black connection went right together.

 

I took another picture. Hopefully it shows up.
Don't use the yellow wire with red stripe from the new part. Just tape it up.
Take the three yellow wires from the new part and connect them to the 3 wires from your bike (in any order).

 

I hooked it up today, not charging more than 14 1/2 volts. But shows around half of the RPMs.
Did yours also change? I guess I'll get used to it.
Was thinking of hooking two yellows together and then put yellow/ red tracer in one of the two yellow red tracers. Yellow /red tracer is for tachometer.