I am having a problem with the charging system on my 03 SP 500. First the battery light came on. I checked the battery and one cell was almost dry so I changed the battery after testing it. So new battery and its still not charging it. I ran through the typical tests and the charging is not doing its job. Checked under the front cover for loose wires ran all the way back from the voltage regulator to the Stator and no problems with damaged wires. Everything is plugged in. The dealer says that its the voltage regulator and they are 70 bucks. ouch.....has anyone else had theres go bad. What sucks is the machine is a year old and only 200 miles.
so is there a way to test the regulator to see if needed befor buying one?

Thanks

 

Rickster, I'm sorry I can't help you with your problem. I was just wondering how do you like the heelclicker clutch kit. How much stronger is your low end power with the clutch kit?

 

I just had the same problem with my 04 - 500 but not with the battery. Pull the cover back off and check the single red wire from the regulator to where it plugs in to the two red wires. My connectors were together but the contacts were not touching. I snapped them together and used a wire tie to hold them and no more problems. Hope this helps.

 

I really like the clutch kit it does add low end to for sure. The factory clutch slipping is also gone. The quad starts to move just off from idle which is great. plus there is no slipping at all. It was the best money spent in a mod yet.

 

wagntwister
its funny you say that cause I checked the red wire and cleaned it yesterday and I went out to check again and it was charging and working fine now. Thanks for the info.

 

No problem I checked alot of things and then spoke to the dealer and he told me what to look for also someone else on the forum told me to look at that.