2000 grizzly 600 new stator and rectifier. Runs great, lights work but only puttIng out 4 volts back to battery.

 

Nothing would work if your battery voltage was 4v, so there is something wrong with your meter. Voltage across battery, when running, should be between 13.5v and 14.5v DC.

 

Sure it would, just like unhooking battery on car while running. Something between engine and battery since engine runs fine. Hoping someone knew bad spot for bad wiring or something. Meter works fine I checked jeep battery and alt.

 

Somebody please HELP!! I've looked everywhere for a corroded connection or anything similar. I can jumpstart or pull start bike and it runs well. But while running I can check voltage with battery in or out and voltage is around 4 volts. Am I wrong thinking with no battery hooked up and bike running I should get around 14 volts? I can understand with battery connected I may now show that much voltage if battery is dying or has a short. I'm at a loss

 

Right, so now I know the problem is the battery isn't charging but the electrics are getting power from the regulator once running. Could be a dud battery, but most likely a bad wire between battery and regulator, this includes negative, so charge the battery up, and make sure it gets to 12v, then check earth on battery, to frame, and to engine as well as the positive side of battery and main fuse, almost all Yams have main fuse on solenoid. The housing corrodes and power doesn't get past the fuse. I check all wires with a test lamp, as this tests for power, not just volts.

 

Could this be a magneto/flywheel issue?

 

Check those wires, easy test, charge the battery up, connect a circa 21 watt 12v lamp between red and black wires on wiring loom plug for regulator, should burn nice and bright, bet it doesn't.