I have been running my little 300 around lately and it has been running flawlessly since i rebuilt it. When I got it this winter, it had a battery in it that was pretty used up and wouldn't take a charge so I replaced it with a new gel battery and it started right up. I believe the old battery being junk was the reason why all the indicator lights didn't work and probably popped when the battery went bad. After riding this weekend, I tried to restart it and the battery was dead. I put a booster pack on it and it popped right off like it did before. I got home and charged the battery up and got my fluke meter out. I would get 12 volts out of the battery as the machine was running and it would only jump up about .1 to .3 volts when i revved the engine, not the 13 to 14 volts that I'm used to on a good charging system. Now I can see why the battery drained while I was driving with the lights on. Where should I start looking at to troubleshoot this charging system? My Xplorer 400 had a problem charging and it was the voltage regulator which was located up by the radiator but I couldn't find it on this machine by just poking around for a little bit. When I changed the seals on this motor, I looked everything over under the recoil and everything looked fine so I dont know if I have an issue somewhere else.

Thanks,
Mike

 

9 out of 10 times it's the regulator when it has a charging problem. Stators are rarely the problem.It's located under the front panel below the cdi module to the right of the reverse limiter module. Can't remember your year model,but here's one for a 98/99 model.Rectifier Regulator Fits Polaris ATV 4060193 4060087 New | eBay

 

Thanks, I was leaning towards the voltage regulator but wasn't sure where it was on this machine. Mine is a 1999 so the one you posted would be the one for my machine. I ordered one that was a couple bucks more than the one pictured but it came with a better warranty so I think it is worth the few extra dollars. I should have no problem getting it fixed by the weekend for the upcoming holiday. My oldest daughter is graduating high school this weekend so we are hosting a grad party at our campground and I'm sure my four wheelers will see a lot of use. We are a pretty dominant polaris campground with a few can ams and a couple artic cats mixed in so having one of mine down would give them guys some ammo to pick on all us polaris crew, lol.

Thanks,
Mike

 

Well, I found the regulator, it's tucked nicely behind the oil tank below the electrical board on this machine. I assume I have to drill out the two rivets that hold the tank on so it can move enough to remove the regulator? Or is there a trick to these that I'm overlooking?

Thanks,
Mike

 

Yep,forgot you have drill out the rivets to get the oil tank out of the way and then either use rivets back on the oil tank tabs or use self tapping screws to hold it.Guess the high paid engineers didn't think about minor things like components going out in the future when they designed things.

 

I got the little 300 up and running again. Took my fluke meter and checked the wires on the sator and everything checked out so I knew it had to be the voltage regulator. Got the oil tank moved a bit and cursed a bit as I used my little mini ratchet with a torx bit to get to the screws that held the regulator on. It charges over 14 volts now and will hold around 12.7 volts with the high beams on and the fan on. Now all I have to keep my eye out for is a newer style clutch cover so I can get rid of the annoying rattle at idle from the clutch running on the plastic cover, lol

Thanks,
Mike

 

You can still use the updated stronger cover and retain your exhaust duct. All the 250/300/350/400/425 models were updated to this part number from the 94 models and up. It's not necessary to get the big bulbous cover used on the later Sportsman 500s,700,800s,etc and have to modify the exhaust duct sleeve if you don't want to. Unless you can find a good deal on the larger covers and can modify the sleeve to fit.

Usage : 5433542

Year Product Model Assembly
2003 ATV TRAIL BLAZER 400 CLUTCH COVER - A03BA38CA (4982568256C01)
2002 ATV SCRAMBLER 400 2X4 CLUTCH COVER - A02BA38CA (4969936993C01)
2002 ATV SCRAMBLER 400 4X4 CLUTCH COVER - A02BG38CA (4974677467A12)
2001 ATV TRAIL BOSS CLUTCH COVER - A01AA32AA (4963816381C001)
2001 ATV TRAIL BOSS CLUTCH COVER - A01AA32AA (4963816381C001)
2001 ATV TRAIL BOSS 325 SE CLUTCH COVER - A01AA32AA (4963816381C001)
2001 ATV XPLORER CLUTCH COVER - A01AG25CA (4963866386C007)
2001 ATV TRAIL BLAZER CLUTCH COVER - A01BA25CA (4963666366C003)
2001 ATV TRAIL BLAZER CLUTCH COVER - A01BA25CA (4963666366C003)
2001 ATV SCRAMBLER 400 2X4 CLUTCH COVER - A01BA38CA (4968366836C001)
2001 ATV XPLORER 400 CLUTCH COVER - A01CG38CA (4963916391C005)
2000 ATV TRAIL BOSS CLUTCH COVER - A00AA32AB (4960076007C002)
2000 ATV XPLORER CLUTCH COVER - A00AG25CA (4954865486C009)
2000 ATV SCRAMBLER 2X4 CLUTCH COVER - A00BA38CA (4954835483C003)
2000 ATV SCRAMBLER 400 CLUTCH COVER - A00BG38CA (4954845484C007)
2000 ATV XPLORER 400 CLUTCH COVER - A00CG38CA (4954875487C009)