location of voltage regulator 2015 ETX Sportsman 325 - Polaris ATV Forum
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post #1 of 8 (permalink) Old 07-09-2019, 05:55 AM Thread Starter
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location of voltage regulator 2015 ETX Sportsman 325

Where is the voltage regulator on this model? Any tricks / tips to replace are welcome.
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post #2 of 8 (permalink) Old 07-09-2019, 06:05 AM
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Up in front of the radiator. 3 yellow wires gives it away. You sure you need one???

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post #3 of 8 (permalink) Old 07-09-2019, 06:54 AM Thread Starter
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Not positively...was told by Polaris to check the resistance across the 3 yellow wires from the stator. If not stator, then voltage regulator. What are your thoughts....the bike started with a jump but immediately died when we disconnected the negative
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post #4 of 8 (permalink) Old 07-09-2019, 07:34 AM
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I'd test the voltage at the battery terminals with the machine running at 3,000rpm. Should have 13.5-14.5vdc.

2011 Sportsman® 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 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #5 of 8 (permalink) Old 07-09-2019, 12:12 PM
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Of course it will die if you remove the battery wire - it needs battery voltage to run - disconnecting a battery wire while running is a good way to fry the CDI or ECU

It is not designed to run without a battery and can damage electronic components by jumping a dead battery and trying to run to charge the battery - charge the battery with a 1.25 amp automatic charger before trying to operate - if the battery dies while running, check the charging system - checking continuity of the three yellow wires is just one step of a multi step diagnostic

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post #6 of 8 (permalink) Old 07-12-2019, 04:01 AM Thread Starter
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Quote:
Originally Posted by latebird View Post
Of course it will die if you remove the battery wire - it needs battery voltage to run - disconnecting a battery wire while running is a good way to fry the CDI or ECU

It is not designed to run without a battery and can damage electronic components by jumping a dead battery and trying to run to charge the battery - charge the battery with a 1.25 amp automatic charger before trying to operate - if the battery dies while running, check the charging system - checking continuity of the three yellow wires is just one step of a multi step diagnostic
I really appreciate the help such as you can provide with your experience. I have an 8 hour round trip to my nearest Polaris dealership. So my EXT is 4 years old and is lightly used...driven by me...the old guy. My battery cells were low which was only visible when I removed the battery. It cannot be revived.

The original was not a sealed battery. My new replacement bought from Polaris is a sealed battery. Measuring the voltage output across the terminals shows the voltage regulator is working properly. I don't want to toast the new battery (by overcharging). We did not check the resistance across Y1-Y3 wires. Can I assume that if the regulator is charging, there are no stator issues?

Thanks in advance.....Jay
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post #7 of 8 (permalink) Old 07-12-2019, 04:50 AM
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The 'regulator' is twofold - it has a rectifier section that changes AC into DC to charge the battery and the regulator section to limit the DC voltage to 14.8 volts to prevent overcharging the battery. The stator produces the AC voltage (upwards of 60 volts) - when the rectifier changes the AC to DC, it cuts the voltage approximately in half, then the regulator limits it. If the conventional battery was low on water, it usually indicates one of two things; either the battery has been overcharged and some of the water has been evaporated out of the acid or the battery is damaged and the plates have absorbed the liquid. A discharged battery will be low on liquid until the battery is charged. Charging drives the liquid out of the antimony on the plates and replaces it with gas. Batteries operate on gas - the liquid is just a medium that promotes the movement of the gas from one plate to another. The gas moves one way during discharge and the opposite way during charging. The natural movement is to discharge. That's why to charge; the voltage has to be higher than the battery voltage to force the flow against the natural direction of movement.

Check the output voltage with a meter across the battery terminals - the voltage should not exceed 14.8 volts. Typically when the battery reaches 14.8 volts, the regulator will cut the voltage - when the battery discharges to approximately 13.2 volts, the regulator will turn off and the voltage will increase to 14.8 and then cut off again.

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post #8 of 8 (permalink) Old 07-12-2019, 05:12 AM Thread Starter
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Thank You for helping me understand. Invaluable experience. Happy trails.
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