2012 RZR 900 XP Voltage regulator and wires overheating.....bad - Polaris ATV Forum
ATV General Discussion General Discussions about Polaris ATVs.

 
LinkBack Thread Tools Display Modes
post #1 of 6 (permalink) Old 06-20-2017, 09:32 PM Thread Starter
Junior Member
 
greengoathead's Avatar
 
Join Date: Jun 2017
Posts: 1
Angry 2012 RZR 900 XP Voltage regulator and wires overheating.....bad

Ok guys, first off, i know this is a RZR question, and i have posted over there too, but this thing is really kicking my butt. any help would be appreciated!

Ok guys, I am really at a deadend.....Long story:
Last fall battery quit charging. Replaced the VR. Still not charging or holding charge, so I bought an Odyssey battery $185. Voltage regulator got extremely hot and buned the floor. I though I had just gotten a bad VR, so I replaced it. Went on another trip and the exact same thing happened. Unplugged and made it back by the skin of my teeth to camp. Got to be a passenger for the rest of the trip, which really sucked. The Polaris dealer thought positively that it was the stator, so bought both a stator and a VR. I now replaced the stator and VR 3 days ago. After running around the block for 2 minutes, I came back to check, and the VR is extremely hot again and the wires coming out of the stator are too hot to touch.
Battery after sitting overnight reads 12.55v
10.8 at the startup hit
14.5 immediately after startup at the battery at an idle
14.4-14.5 at 3000-5000rpm with NO jump during rev or decline from 5000-1200
unhooked the red and black wires from VR to battery and they test at 14.3 up to 14.78 revving to 5000rpm.
hooked back up to battery and again 14.55ish at idle-5000rpm.
unplugged harness from stator to VR and tested all 3 wires at [email protected] // [email protected] // [email protected]
checked ohms on stator at 1.2
pulled the ground wire from frame, wire brushed both the frame to bare metal and connectors are polished shiny bare metal.
I even ran another ground from the battery to the frame in addition (temporarily) and continues.
Battery checked out perfect and borrowed a battery from a buddy, and the exact same scenarios continue to happen.
I am at a complete loss.
Why do I seem to be getting an overcharge and losing VRs? When I changed the stator, all looked normal in there, and I saw just a tiny bit of oil in the stator cover. reading in other places, this is not abnormal, but it seemed odd to me.
Please let me know your ideas, I am at a real loss at this point. This charging system is pretty dang basic and it really has me baffled.

UPDATE: used buddy's battery and same thing. all wires/terminals have been cleaned and reinstalled.
HELP!!!!!!!!!
greengoathead is offline  
Sponsored Links
Advertisement
 
post #2 of 6 (permalink) Old 06-21-2017, 05:16 AM
Premium Member
 
bp405's Avatar
 
Join Date: Sep 2011
Location: New York
Posts: 7,208
Bad wiring is my thought. Go through the wiring harness and look for grounded or shorted wires.

2011 SportsmanŽ 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 SportsmanŽ 570-T
2019 AlumaŽ A8818
2020 OutlanderŽ 1000R XXC (on order, ETA mid-Sept)
bp405 is offline  
post #3 of 6 (permalink) Old 09-14-2019, 11:53 PM
Junior Member
 
billvwi's Avatar
 
Join Date: Sep 2019
Posts: 2
Hey did you ever get a solution to the overheating regulator ? I'm on my 3rd one..


The regulators have never been on trail. Wires start overheat as soon as it starts. One is a Mofset relocation kit. All higher end quality products.


Thanks.

Last edited by billvwi; 09-15-2019 at 05:10 AM.
billvwi is offline  
Sponsored Links
Advertisement
 
post #4 of 6 (permalink) Old 09-15-2019, 03:36 AM
Premium Member
 
bp405's Avatar
 
Join Date: Sep 2011
Location: New York
Posts: 7,208
Chk these out https://squareup.com/store/cycleworx...timate-package. Seems to be the answer. Just a better built component designed for the abuse seen out on the trail.

2011 SportsmanŽ 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 SportsmanŽ 570-T
2019 AlumaŽ A8818
2020 OutlanderŽ 1000R XXC (on order, ETA mid-Sept)
bp405 is offline  
post #5 of 6 (permalink) Old 09-15-2019, 05:11 AM
Junior Member
 
billvwi's Avatar
 
Join Date: Sep 2019
Posts: 2
Wires start overheat as soon as it starts. One is a Mofset relocation kit. All higher end quality products.
billvwi is offline  
post #6 of 6 (permalink) Old 09-15-2019, 12:44 PM
Polaris ATV Legend
 
latebird's Avatar
 
Join Date: May 2014
Location: Illinois
Posts: 4,512
Do you have any high current accessories? Is the battery the original size? Poor connection between wiring harness and the VR unit will cause hot wires.

Shop Owner and Mechanic with over 50 years experience
latebird is online now  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris ATV Discussions > ATV General Discussion

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome