Charging problem on 2002 Polaris Sportsman 500 HO
 

Bought the bike used, with low hours on it. Guy said it just stopped charging. I tested the regulator, it was bad. I noticed that the reg, was changed at least once already. Bought a new one, and it lasted 1 week. Stator tested fine. The red wire to the reg, had heated up enough at the connector, that it melted the plastic, and it failed.

Any ideas?
:thanks:

Alternator Output Test
I. Place the vehicle on level ground and set the
parking brake.
2. Remove the front fender front cover as described
in Chapter Fifteen.
3. Follow the electrical harness from the alternator
to the location where it connects to the voltage regulator.
4. Disconnect the individual yellow and the
yellow/red electrical connectors from the voltage
regulator (Figure 7).
5. Connect an AC ammeter to the yellow and the
yellow/red stator wires leading from the alternator.
Crank it with recoil start only! Then see what amperage you're showing.Manual calls for 7 amps. Could be a stator problem or the regulator you have was faulty.

Do you have a new battery in it?