I am having trouble with my polaris xplorer no headlights no 4x4 no battery charge no indication lights runs great I get 25-30 volts to kill switch it's a black wire I also hooked up battery charger to battery and it shorts out unless kill switch is in off any help would be great thanks

 

First off shouldn't be more than 12 volts going anywhere other than 14 volt charge going back to the battery from the regulator rectifier when at an idle.Several things to check.Check that the battery is good,load test it if in doubt.You can pull start this model even with a dead battery.Up from the battery is the main 20 amp circuit breaker in a sealed pouch that allows power to the lights,bulbs,ignition switch,etc.Check that it has 12 volts on either side of the red wire leading in and out of it. You can always slice the pouch open and check if the terminals are corroded. You can get this breaker if needed at any auto store. Could have a shorted out kill circuit black wire either in the left control switch,ignition switch or even the black wire from the cdi module could be shorting out internally causing problems. When moving the switch causes problems that kinda lets you know right there you probably have a short.

 

I thought you are suppose to get high volts from the stator then the rectifier/regulator dropped down the volts, the black wire from the cdi I get 27-30 volts,

 

This may help a little as we're talking ac voltage coming from the stator,then changes to dc voltage along with reducing voltage to a max of around 14 volts dc back to the battery.
"The first step in troubleshooting a charging system is to determine if the stator is putting out enough AC voltage. To do this, simply locate the stator leads (usually two wires together in the same harness coming out from beneath the flywheel or out of the alternator), run the engine at full throttle, disconnect the stator leads from the wiring harness to the battery (which temporarily will not harm the components) and, with your VOA meter set at AC voltage, touch the tester leads to the two stator leads. You should read a relatively high AC voltage--somewhere in the 27 to 45 volts AC (VAC) range. If you have a technical manual available for your machine, check the specification in it or call your dealer to see what it should be. If this test is good, then your stator should be okay.

Next, locate where these two wires go into your regulator/rectifier. You may need a wiring diagram to do this, or you may be able to trace the wires on your machine. Check for the proper AC voltage going into your regulator/rectifier. If you do not have about the same voltage there as you did at the stator leads, then you have some bad wiring between the two.

Assuming you have the correct AC voltage going into your regulator/rectifier, you must then find the wire that sends DC voltage to your battery. It is usually red, and you can normally trace it on your machine or use a wiring diagram to locate it. Set your VOA meter to the DC volts scale, clip the black lead of your tester to a good ground on your engine (or your battery's negative terminal), run the engine at full throttle and touch your tester's red lead to the charge-wire terminal on your regulator/rectifier. You should read about 14 volts DC (VDC). If you read less than 12 volts, then your regulator does not allow enough voltage through to charge your battery. If you read high voltages, you may be overcharging your battery. Check your technical manual or call your dealer for the exact specification."
This is just a generic post,but where you really need the factory service manual to guide you on tests. Hard to find a free one for the Xplorer 400,but here's one up to a 98 model 400 that may help.http://gh-ftp.com/ORV%20Manuals/Pola...e%20Manual.pdf OR here's one for your specific model for 10 bucks. Better than just chasing your tail around trying to find electrical problems. Polaris ATV Manuals

 

I get 18 on low idle ac and as I rev up get 32 ac I get 8 volt dc after regulator low idle and 18 dc on high idle, so that's probably one of my problems, but coming from the stator I have a black wire that goes to my cdi box then to key switch, kill switch, and 4x4 that I get 24-32 dc volts?

 

Pull the black wire from the cdi and then see if you're still charging 18 volts from the regulator to the battery. If you are,then as you say you may have more than one problem. Look at the specs in the manual for resistance checks on the stator itself.If resistance specs are off more than 20% + or - of the listed values then the stator may be the cause of the over charging plus it can burn out a regulator rectifier also.