I love my 800 BUT, i have an overcharging problem. When it is at idle it is putting out about 13 volts. But as soon as you get it above idle it jumps up to 18 to 19 volts and the battery warning starts flashing. i have taken it in to get fixed four times and they always say that they have fixed it this time,it works for about 20 mins and does it again. so far the regulater and computer have been changed twice. Could the stator be doing this? any help would be greatful. Please help, I love my 800, i miss my 800.

 

well as you already know its the recifier that controls the voltage being put out. but you said they replaced it? the ECM does also play a part in what goes on. dont know if thats what you ment when you said they replaced the computer or not(seprate item) but i would be asking them right up front what they did to fix it for sure. did you try r tester on the battery out put or going by the speedo pod? just for the heck of it try checking w/ a real tester to confirm it isnt a bad read. imo.

 

Yes i ment to say they replaced the ecm, not the computer. And they showed me the parts that they replaced. i have always had good luck with this dealer and it does work when it is there. just doesnt work when i get it home. and i tested with my fluke dmm. the more rpm,s, the more voltage!

 

Maybe the ecm orthe rectifier they put in went bad already, they should stand behind their work for a litttle while. How long did it work correctly?

 

They changed both ecm and rectifier twice, i think that it could be a bad connection problem or stator. i dont know if i bad stator will cause an overvoltage or not. just looking for ideas....

 

Today i took another look at the charging system. i still have the old parts from the dealer. i put them back in and nothing changed. There is a post for a 2008 800 repair manual, will that be the same for my 800. i need to find an wiring schematic for this thing. im getting real close to putting a match on this thing. it sucks to have an 800 you cant ride!

 

i know that caper another memeber has had 3 ecm's in his 450 that went bad(replaced free i beleave) to finally get his straighten out. again you could ask, but i dont beleave it would be the stator as the recifier is what controlls the voltage output i beleave. make sure to check all the grounds by remeoving them and putting dielectric grease on them when reconnection them as a few people have had issues w/ this and have caused wierd problems. just an idea.

 

Fixed it. Thanks Stendori. I have already checked the ground from the rectifier in the past. But after you suggested it, i did it again. i found that the ground wire from the rectifier just under the gas tank was broken inside of the insulation. i ohmed the wire from the rectifier to ground and could get up to 60k ohms just by moving the wire. I replaced it and its working great. I guess that the rectifier measures the incoming volts to ground and the high resistance was causing the high voltage output. The wire looked fine just looking at it but when i took the insulation off it just fell apart. Thats why it worked sometimes. the wire was not burned, i think it was a defective because it only had half of the wire strands in that section of the wire than at the ends. I am and electrician, i couldnt understand why i was having such a problem troubleshooting this. This just goes to show you not to assume that its always a component problem. Thanks again everyone for the help!

 

Nice work finding the issue and fixing it. Kudos to stendori for pointing you in the right direction.