yes sir, I am confident enough to order a new rectifier, especially at the prices at your prescibed website. That's some serious savings over OEM.

Again Thank you for your time and patients, I know I am not the most skilled at this and you helped me through it. Can't say enough of your willingness to assist. Well done.

 

Double check that your battery terminals are tight. You'd be surprised how many people don't ever check this! Could be the cause of the intermittent charging and the awd light problem. If the connections are tight and you're sure the battery is ok,then order the regulator/rectifier. Also don't thank anyone until you have the problem solved! I could be leading you over a "fiscal cliff" like Obama and Boehner are fixing to do to us as a nation OPT

 

Point taken, I did check the resistance on the stator( yel - yel/r wires on VR), and there is power (red wire) to the voltage regulator. Just want to confirm the Voltage reg is the culprit. I'll check battery connections to confirm. Any other checks I could do?

 

I'm about all checked out 12 volts should be on the red wire of the regulator/rectifier and if the charging is erratic,then it could be the problem. Strange though when you had the tires off the ground and the awd light came on and voltage increased. Could just be the regulator surging? They can under charge or over charge. If voltage stays between 14-14.5 at the battery (at or above 3000 rpms) possible that it was just a ground/connection issue? If the voltage does fluctuate a lot while holding throttle steady,then I can see it being a regulator problem. OPT

 

Update

I replaced the regulator and with positive results, I have 14v consistently at Idle and at rpms.

With the new regulator situation is better but mot fixed. Still have lost the AWD while snow plowing.

When you question the ground, what do you mean? I think you are on to something questioning the ground.

When I was checking the system with a volt meter, more than a few times when I touch the circuit wire and ground to chasis the AWD light comes on?

 

Which circuit wire are you talking about? If it's the ground wire and it's completing the circuit,you may have to tie into the ground wires from the coils to another good ground to enable this system to work. I also forgot to ask if you have the FB model that has the speedo,but even if you do this speedo is different than the ones that have the awd circuit going through them(as best as I can remember) such as on the Sportsman 500. I don't have an electrical schematic on the 2001 Magnum 325 but will check to make sure. OPT

 

The wires I am refering to are the Gray, gray/white and brown/white wires running from the coils to the AWD switch on the handle bars. Also the gray and gray/white wires running from the trans switches to the AWD switch.

 

Try jumping the brown/white wire from the awd switch to a known good ground(brown wires). Same thing that people have done on the speedo harness when the resistor in the speedo burns out. They just bypass it and tie the brown and brown/white together,but you loose the speedo function to gain awd. OPT

 

I'll give the jumper a try. Here's someting to think about: Last night and today day the situation was similar when the engine is cold no AWD, after running for twenty to thirty minutes it works no faults for as long as I keep it running. Once it cools down again I have to let is idle to heat up and then it works? I would appreciate any comments.

 

Cold fluid,wrong type fluid can cause this until the hub fluid warm up.Demand Drive hub fluid only. Plus can still be an intermittent ground problem. OPT