I've read a couple of threads and posts regarding charging system issues, but non specific to my issue and was hoping someone here had some experience with this issue. I'll start with explaining the issue the best I can. Keep in mind I have pretty much zero knowledge so I might get some of my terminology wrong

I bought this bike used about 2 months ago and within the first couple of days it started having issues with charging system. I tried to start it one day and it ended up being complete dead. First thing I noticed was I had 3 cells almost completely drained in the battery. I filled them up and charged it overnight. I brought it to a mechanic who gave me the explanation that I apparently tried to hard to start it and it fried a selanoid and grinded the teeth on the bendex. He replaced those pieces and all was good for a while. But than the starter started acting up sounding like it was missing but eventually it starts. He did say I might eventually need a starter and offered no explanation for why the battery was draining. However, the battery hasn't drained since I got it back, but it does have low voltage testing off and while idling or pressing the throttle. Somewhere just over 11 volts.

I decided to take the side covers off and the front rack to see the voltage regulator and I found this burnt looking wiring harness. It also looks like the previous owner played around in there too as all the wires are taped up with electrical tape assuming factory wouldn't have done that?

Last thing is that the battery warning light is coming on after long rides. But bike still starts fine.

Pictures of burnt cable below....

 

11 volts won't cut it. You can do a general check on the stator yellow wires leading to the regulator. Should show some resistance between each yellow with no short to ground. If this checks out then replace the regulator. Load test the battery after fully charging it. A faulty regulator can suck a battery dry and down quick and cause plates to short out. You can show good voltage(12.6-12.8 volts) but may fall on its face with a load test.Here's a good article on this. https://www.batterystuff.com/blog/ho...ry-is-bad.html

 

Thanks. The time that I refilled the cheeks and put it on slow charge all night next day battery tested good. But it has drained since putting 300km in the ATV. And I get that battery warning. I wonder what role that burnt connector has with these problems. Going to read that article.

 

One problem could possibly be the connector itself if it got hot and wires shorted out. Pull it apart and check wiring. Connectors are available at most auto houses that you could make work if need be plus several places online.Motorcycle Connectors A faulty regulator could have caused the connector to over heat or you may get lucky with just a new connector if needed.

 

Yeah Polaris dealer trying to tell me I'll have to buy the whole wiring harness ($479) can't just get the connector which I find odd. Once I find someone to test voltage regulator to rule it out and change that connector I'll have a better idea.

 

Here's the connector looks pretty bad. Hoping can find a generic connector so don't have to wait to order one.

 

Is it possible to just use a generic water proof connector to reconnect the wires? Or does it have to be specifically designed for the purpose?

Thanks.

 

I don't see why you can just splice the wires together and wrap with heat shrink. Coincidently, had the same thing happen to my Arctic Cat, I started seeing 11volts on my Trail Tech Voyager. Bought a new regulator, dug into it to replace the regulator, found similar burned wires. Now I'm going to test my original 7,000 mile regulator, it may be fine.

 

You think it's very high chance the voltage regulator caused this? I can't find any simple instructions online on how to test the voltage regulator. I don't even know how to set and use the multimeter for this. Most instructions are given thinking you know the basics. I need basics lol First ATV and trying to learn this without spending money on mechanic all the time.

 

Test the regulator same as the stator wires. Should show some resistance between each yellow regulator wire. If wires zero out,regulator is trash. Tested several regulators this way. I would get a good connector for this from any local auto supply or the site I referenced. Just take one end of the connector in to show the parts guy and they can match a connector up to the size connectors you need.