I've been working on my polaris xplorer400 (1995). Had it running and everything seemed fine. However, one the battery was dead. Charged in w/ a charger and had it tested. Everything was fine so I connected a meter to the battery when it was running and it was only showing 12.4 volts. Reved it up to approx 3000 rpms and there was no change. Turned the light on and it started dropping. I checked out the wiring to the reg/rec and found a wire that was cracked in a couple places. Red wire near the reg/rec. repaired the wiring and retested the charging. Seemed to be working. With lights off and at approx 3000 rpms was showing between 14.4 and 14.6. Turned the lights on and tested at the same rpms and was showing between 15.3 and 15.55.

Was wondering if this was to high and if would cause a problem?

Thanks,
Steve

 

The red connector was always coming loose on these regulators. They can undercharge or overcharge. I've seen them go as high as 18 volts which all it does is makes the batteries run hot and purge out battery acid from the overflow tube all over the rear of the clutch cover. Lights on or off it shouldn't charge more than 14.5 volts. Shows on the Polaris website yours takes #4060133. Here's a cheaper place to get one.Polaris ATV Rectifier Regulator

 

Thank you for the knowledge and information on where to purchase one.