I have been over every message on this board and others related to the STATR ERROR message on Polaris ATVs. I've checked the ground. Everything is secure. The machine only gives the STATR error when I am riding and I begin to move above idle speed. When I sit in neutral and get the RPMs going high the machine does NOT give the error. (Or if I ride slow on level ground.) The diagnostics shows voltage as 12.3 no matter at idle or when the RPMS are high.

My machine is a 2002 Sportsman 400. I've replaced the stator, the regulator rectifier and the CDI with Caltric parts. None have relieved my STATR error issues and I have re-installed rthe OEM parts.

I see OPT recommends the Kokusan ignition upgrade kit for people with the Sportsman 700.

Is there a similar kit for the 400 machine?

Thanks. This is a low milage machine that belonged to my father in law. It is a great machine and I really just want to get it back into working order.

Chuck

 

Updated Kokusan kits were only for the 600/700 atvs. If you've replaced the stator and regulator with aftermarket parts and the charging still shows battery voltage,then best to retrace your steps on this. Simple wire disconnected from the regulator could be the problem,faulty ground or the Caltric stators themselves can be a hit or miss as far as reliability as well as the aftermarket regulators. My preference would be Ricks stators,but they are higher priced. You can do a basic test on the stator by checking that all yellows that run into the regulator. Should be some resistance between each yellow and no yellow shorting to ground. Same general test for the regulator,resistance between each yellow,no shorts to ground. Best to have the manual if don't have one as it shows trouble shooting guides and steps along with stator resistance specs to help you narrow down the problem.2002 Polaris Sportsman 400 Service Manual PDF Download

 

Thanks. I suspected they may only be for the larger machines. I have the PDF service manual, but I am getting a real print copy this week in the mail. I will go over the wiring and diagnostics in the service manual once I get the real copy. I can't work with PDF like that.

If I don't find anything I will order the same set of parts from Rick's.

The only thing I didn't replace was the coil. Do you think that the coil could cause that error? The machine idles and runs fine. Just getting the error.

Do you think it hurts the machine to run it until I can get rid of the STATR error?

Thanks so much!

Chuck

 

Runs and idle at least is a good sign.. Keep the battery on a maintainer to keep it from being sucked down until you find the problem.Hope it's a simple faulty regulator. If the coil was bad it wouldn't be running at all.

 

Unplug the 3 yellow wires from the stator , start it up and check AC voltage across the yellow and yellow/red , should be well in excess of 25 volts AC { could be as high as 50 volts AC } , then check yellow to yellow/black and it should about half the voltage of the first test , same for the yellow/red and yellow /black , about half of the first test .
If this checks ok then the stator is good then move on to wiring problem as OPT mentioned or faulty regulator .

 

Thanks. I will test that today.

 

I tried removing the three yellow wires that lead from the stator to the rectifier/regulator. The machine would not stay running long enough with these removed in order for me to test voltage levels.

I'm still waiting for my physical service manual. So once I get that I will review as much of the wiring as I can.

Thanks.

 

Can't use electric starter when you do these tests. Recoil start only. Try this and see if it works.

Alternator Output Test
I. Place the vehicle on level ground and set the
parking brake.
2. Remove the front fender front cover as described
in Chapter Fifteen.
3. Follow the electrical harne ss from the alternator
to the location where it connects to the voltage regulator.
4. Disconnect the individual yellow and the
yellow/red electrical connectors from the vol tage
regulator (F igure 7).
5. Connect an AC ammeter to the yellow and the
yellow/red stator wires leading from the alternator.
6. Shif the transmission into neutral.
CAUTION
Do NOT start the engine with the electric
starter; as the ammeter will be
damaged.
CAUTION
Do NOT conduce this test for longer
than 10-/15 seconds or the alternator
windings may overheat.
7. Start the engine with the recoil starter and let
idle.
Average amperage reading is 7 amps


If you can't do this test just simply do a resistance test on the yellow and yellow/red stator wires. Should show around 0.13 ohms with no yellow shorting to ground.

 

Your battery is either discharged or needs to be replaced if it won't stay running with the stator disconnected .
Have you had the battery tested ?