Anyone?

 

Voltage regulator problem, sounds like it is overcharging.

Check the charging system.

 

What he said^^^^

 

Is there a way to check the charging system specifically the voltage regulator? Where is the voltage regulator located on a 2007 Sportsman 500? Once again, I changed the battery hoping it would resolve the issue but it did not.. So we can eliminate the battery.

 

Where is the voltage regulator located on a 2007 Sportsman 500? .

[I have the service manual....

I'm confused.....

 

I found the thread below on checking the charging system but not sure if it is applicable to a 07 Sportsman 500.

http://www.polarisatvforums.com/for...orums.com/forums/polaris-xp/41442-how-test-your-charging-system.html#post282650

 

Yes. I should recommend a service manual for your wheeler. You can download a pdf version to your computer. I know it has saved me hours of shop time having that information on hand.

 

I have the service manual....

 

I found another thread with a person having the same problem as me..

http://www.polarisatvforums.com/for...rums/atv-repair-maintenance/43847-battery-warning-light-flashes-higher-rpm.html

I will check with the poster to see how he resolved the issue.

 

The poster on this thread was having the same problem as me, however; I sent the poster a private message but he has not responded back yet..

 

Check your battery voltage not running should be 12 to13 volts then start it up recheck batt voltage while reving the engine shouldn't read any more then 14 to 14.8 volts or so if its considerably higher u need a regulator

 

Ok.. Will check it tomorrow....

 

Is there a way to verify that the stator is not the problem? The voltage regulator for my ATV is $350. I want to make sure I purchase the correct part.

 

Anyone?

 

There is a procedure for testing the stator in the service manual.

What voltage did you get on the battery at RPM? It is the regulators job to take the 60vac from the stator, rectify it to DC, and regulate it to 14.5sh VDC.

My PDM had water intrusion. It has 4 screws on the back of it that hold the cover on. Had lots of corrosion in mine. Might be worth checking.

Sean

 

I ran the test this afternoon. The DC volts reading on the battery without the engine running is 12.80 volts. With the engine running and with RPM, the battery reading is around 14.60 volts. It will not exceed 15 volts even with high RPM. So based on that test, it looks like the voltage regulator is working. So, what's next to check. Once again, the only modification to the ATV is an oversized piston.

 

Have you had the battery load tested?

Sean

 

This is a new OEM battery from Polaris... It did the same thing with the old battery. I thought replacing the battery would solve the problem.. So I don't think its the battery. What's next to check?

 

The ignition coil could be weak. At higher RPM it has to create a field and collapse it much faster than at lower rpm. What you may be experience is the coil breaking down.

Check your primary and secondary resistance of the coil. Also, while you're at it, check your plug wire. If there is any cracks on it then consider replacing it.

 

So at this point have we ruled out any issues with the stator as well? I will check out the ignition coil and plug wire.

 

You said the voltage would not exceed 15 at RPM. Did it get to 15 VDC? I ask because the service manual says it should max at 14.8 VDC.

Sean

 

It does not get to 15 VDC at all. You are correct is that the max reading I got was 14.8 and not 14.6 at RPM...

Once again, the battery light only flashes when I get to 50-55+MPH when riding on the highway to and from the trail head. The battery light has never come on while riding on the trail. I have made a engine mod as stated in my first post. I will ask the question again, does this ATV have a MPH or RPM limit and it will start shutting itself down once it reaches that limit?

 

Well, there are ways to test a stator, but I don't see a max voltage. I will look at the manual more when I get home. From memory, I think it says each leg of the stator should be 30-40 VAC at 3-4000 RPM. There are three yellow wires that come from the stator. You would need to test 1 to 2, 1 to 3, and 2 to 3, if that makes sense. First ohm them all out with the quad off. Should be relative zero (.43 ohms). Then check each wire to ground, should be open (no continuity). Then check the voltage above.

I have not seen a bad stator yet, and from waht I have read, it seems most of the bad ones do NOT charge, and/or are physically damaged. Your charging system seems to be working correctly. It just seems like there is more of a draw on it (the charge system or battery) than it can handle at higher RPM. As a comparison, when my battery was going bad on my 2006, I got no battery light under normal use, but when I used the winch, the battery light came on and eventually killed the battery.

The polaris battery I had in my 2006 was a YAUSA brand battery and was a VERY good battery. It lasted 7 years and finally crapped out. You said you put an OEM battery in it. Is it actually a Polaris or YAUSA battery? I ask, because my Polaris dealer sold me an off brand battery when I went there to get a battery for my 2008 Sportsman 300. Brand was something like "bikemaster," and it was junk. Went bad once, I got it replaced under its warranty. It went bad again, I just junked it and paid for an AGM out of pocket. No problems since.

Is there a way you can test the quad with as much turned on as possible. IE lights, any accessories on, etc. In short, with more drawing on the battery/charge system, if the problem happens sooner (would indicate the system is not keeping up) or later/not at all (would indicate it is over charging).

Sean

 

The new battery is a YUASA battery.

 

Not sure what the next steps are to troubleshoot this problem. Any additional advice?

 

I have a 2010 500 and my bike does not shut down. I can floor it until it is maxed out. No loss of power just that is all the faster it can go.

 

Anymore recommendations?

 

Anymore comments?

 

I sent you a private message check it out..