Can anyone help...i have an '03 kvf 360 4x4...battery not charging...thought it was the battery so replaced the battery. Checked battery with a volt meter and only charging at 5.30...anyone have any idea what the problem might be...stater, regulator...or how i would go about checking it.

 

Either you have a bad voltage regulator or a bad alternator.
1). Find the alternator connector - white plastic round connector (3 black wires) coming out from the engine side. Disconnect it.
2). Label the 3 black wires, like 1, 2 and 3.
3). Start the engine with a good battery. It would start with the alt connector disconnected.
4). Set your voltmeter to AC range. Check AC voltage between any 2 black wires coming out from the alternator/engine side.
5). Have your little bro rev up the engine to mid throttle in NEUTRAL.
6). You need to measure 3 AC voltage readings from 3 different combination like 1&2, 2&3, and 1&3. The reason you are doing 3 readings is because there are 3 sets of coil windings in the alternator. Each reading must be higher than 36 VAC. If any of 3 readings is below 36, your alternator is shot.

 

Ok i will try that tonight. Thanks alot i will let u know.

 

Well i just did the test and the readings were 25,27,29

 

I would say your alternator is OK with that kind of output. Put everything back and start the engine again. This time, measure the DC voltage at the battery terminals while your little bro is AGAIN revving the engine at mid throttle. If it's less than 13 VDC, your regulator/rectifier (one part doing 2 things) is not doing its job.

 

Ok just went out and did that the volts was 8.63

 

Well, you just completed the diagnostic test for your charging system problem. Your charging system is producing enough AC output but it's not getting converted to healthy DC (13+) to charge your battery. You have either bad voltage regulaotr/rectifier (most likely) or the connection problem at rectifier. Before replacing the part just make sure all connections are tight, clean, no corrosion/debris, since the voltage regulator (P/N 21066-1112) is not cheap (~$140+) from a Kawi dealer.

 

Well i try the regulator off my 650 and it still not charging.

 

stang....

not to seecond guess you, but how did you go about the new battery...
did you fill it yourself or wasi t filled when you got it.
If you did it yourself, how long did you let it stand before putting it in and running machine...?

I put myself through the battery learning curve with the kids atv....
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The battery was filled and charged when I got it