Have the red lead of the meter on the Yellow wires,the black lead to a good frame ground or where the brown leads group together(ground). Should show a small resistance reading. If the ohm meter zeros out then the wire has shorted out in the stator.

 

Thank you. I’ll test that this evening.

bob

 

OK. I got a reading of .5 resistance on both wires. Is that bad? I know it’s out of spec, but what does it mean?
None of the wires are grounded.

Btw, all of the components are new (stator, flywheel, resistor, coil, CDI, pretty much every electrical component was replaced during the rebuild) Now I have replaced the rectifier, but I replaced it with a used one from ebay.

 

When you said a "used one from Ebay" I think you may have found the problem. Some meters when you cross the posts don't always zero out also. You can be off a little one way or another. The 0.3 average resistance on the stator wires is + or - 20%, so sounds like you're ok especially with a new stator.Order a new regulator and see if it solves the charging if you've eliminated any wiring problems,shorts,etc. Polaris ATV Rectifier Regulator
It should show LR39-1 on the old regulator,if you got the correct one from Ebay. If your model isn't listed on the link,just give em a call and they should be able to help you.

 

PSEP doesn’t carry my specific rectifier.
I guess I have to shell out the big bucks and buy it from a Polaris dealer.

 

How about this one? Have you ever heard of these people? Does it sound legit?

Regulator Rectifier Trail Blazer 250 400 Polaris

So many questions, too little time.

 

The main thing is to check your leads versus the one in the pic if this is the actual one you'll be getting. Sometimes "one size fits all" may not work,but if it does,it's about half the price from one at Polaris. It does say at the bottom that it replaces #4060208 which is you part # on the Explorer.