[cmechanick850ho]

So im having an issue with my 16 sportsman 850 on recharging the battery (low voltage code showing on display) and im running out of ideas. It started when i installed a new battery. I have a multimeter so i tested the battery. Battery reads 12.8v which to me means theres nothing wrong with the battery. Then i started to troubleshoot the stator and voltage regulator/rectifier. Ive watched countless how-to videos, read many diagnostic articles, and even asked some friends and coworkers who are familiar with powersport equipment, and still have a low voltage reading on my display. I tried to "ride it out" to see if its just my display and after a couple hours, sure enough my battery was dead. I tested the stator first because the voltage regulator is less than a year old. I did both static and dynamic test and got mixed messages when it came to the results. The static test shows nothing, no ohms or open line. The dynamic test shows the AC current i should be getting. Btw i belive it is a 3 phase stator. So confused i test the voltage regulator and its fine (i dont remember the results). I tried one method of checking ground on the stator bc its still on my machine, and that was fine. But still have low voltage. Im no expert when it comes to this kind of stuff with electricity and AC and DC and all that. So im reaching out bc idk what is going on. Any help is better than none. Thank you

 

[kcaves]

Try to test the resistance on each phase of the stator cold and hot. They tend to show their problems after they’ve been working for a while


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[cmechanick850ho]

Try to test the resistance on each phase of the stator cold and hot. They tend to show their problems after they’ve been working for a while


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Ok so im assuming run it for awhile until it starts giving me issues, then test each phase while its hot, then test again cold. Ill give it a shot. Thank you

 

[yooper265]

You should be getting a minimum of 25 volts AC across each of the three stator leads { phase to phase } when unplugged and engine running , if this checks ok , replace the voltage regulator { again }

 

[yooper265]

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[latebird]

You should be getting a minimum of 25 volts AC across each of the three stator leads { phase to phase } when unplugged and engine running , if this checks ok , replace the voltage regulator { again }

You should get about 25v AC at idle on an open circuit (not plugged in to the rec/reg) and up to 95 volts AC at 5000 RPM on each phase (3 wires of the same color generally yellow) A, B and C - check A-B, B-C and C-A. The readings should be near the same for each phase. Ohms phase to phase should be low and near the same - ohms to ground should be open loop any phase to ground.

Next test - closed circuit: connect the stator to the rec/reg and check AC volts phase to phase - should be lower than open circuit, but approximately the same phase to phase and has to be over 30v at about 2400 RPM and above (migh have as much as 45v AC at 5000 RPM).

If the stator passes those tests - move on to testing the DC: First test the battery - charge the battery fully on an automatic charger with no more than 1.5 amps output. When the charger indicates a full charge, remove the battery from the charger and let stand for 4 hours. Check the battery voltage after standing - it should be no less than 12.8v and would be better at 13.2. If the battery self discharges to less than 12.2 volts, get a new battery and properly activate it before installation. With the battery installed, connect the volt meter across the battery terminals - check the voltage with no load, check with the key switch on and all accessories off - start the engine and watch the voltage as engine speed is increased - above 2000 rpm, the voltage across the battery terminals should start to rise increase the engine speed to about 2500 to 3000 RPM and watch the voltage rise - holding the engine at a steady speed, the voltage should steadily rise to no more than 14.8v - at around (slightly more than less) voltage, you may see the voltage decrease to 13.2 and then begin to rise again - this is indicative of the regulator turning on and off. An FETMOS style regulator may simply maintain a voltage between 13.2 and 14.8 volts.

Final test - switch the meter to the AC scale while connected to the battery - it should display meaningless random values - if it displays a constant value, that is indicative of AC getting through the rectifier and AC of any value will kill a battery in a short time.

Let me know if this helps

 

[Sprotsman]

If it ends up being a voltage regulator I’d go with a higher quality version. Either a RicksMotorSportElectrics or CycleWorx!

 

[FPD218]

What he said