98 XC600 voltage regulator questions - Snowmobile Forum: Your #1 Snowmobile Forum

69CRUZR · 01-24-2012, 07:36 PM

So I have read all the posts on here about voltage regulators and how to check them etc. While checking my voltage regulator its reading about 13.5 VAC at idle, but when I bring up the RPM's it will drop down to 10 - 9 - 8.5 when it gets up towards clutch engagement...

My issue is that this is a brand new Polaris OEM part to replace my original one and Im getting the exact same reading I got before I installed the new one. This regulator is not exactly the same on the outside and etc but is their replacement part for my original. Its installed correctly with a good ground.

The reason for me replacing the voltage regulator is that occassionaly while riding last year my lights (all of them) would sporatically go VERY dim. Sometimes would flicker in and out with revving the engine, sometimes not. Give it a minute or two of this and then they would all be fine again and I would continue on my way on the trail... There would be loooong gaps of time between the sled having issues and it was so rare I didnt worry about it right away. Towards the end of the season it became more common, and at the very end of the season I broke the skirt on my PTO piston and did a full rebuild. Crank rebuilt, top end, everything. But I did re-use the stator, flywheel, and all electronic, ignition components. After I got the engine back together, little bit of run time and I put it away for summer. At the beginning of winter I noticed it doing the dim light issue still, and more commonly so I decided to investigate. Thats my novel of how I got to where Im at....

Any ideas?!?!

69CRUZR · 01-24-2012, 07:51 PM

Also forgot to mention that my lights had no issues in the hour or so I was riding the sled last night. This is right after new voltage regulator install, but still was getting the readings which went down from 13.5 VAC as I revved it up.

In addition, I included some pictures of the stator and everything in that general area that I happened to take 6 months ago while doing this engine rebuild. I know sometimes people talk about rusted magnets etc, not sure how mine looks but assume its functioning correct as it worked fine the whole time I ran it after new regulator, and 99% of the time for the 3 years I had the sled before that.

robhill1965 · 01-25-2012, 10:30 AM

You might check the ground wire in the harness between the hood and where it connects near the stator. I had a similar problem and just threaded a new ground wire in there to fix it. It was intermittently losing connection. I never actually found where the defect was but changing the wire cured it.

mmgg · 01-25-2012, 10:39 AM

you could check the volatge output at the engine before the regulator it'll be around 14 volts

TwinsofMLB · 01-25-2012, 01:13 PM

Check the wires under the seat for chaffing. A voltage regulator issue usually doesn't come and go. Most likely a short ground somewhere.

69CRUZR · 01-25-2012, 06:12 PM

I checked the wires under the seat when I put a new seat on it last week, all seemed well. The big mystery to me is the dropping voltage reading as the RPMs increase...makes no sense to me...

Correct me if Im wrong but getting solid voltage readings repeatedly, (bad readings at that) and the lights never flickering anymore would indicate no ground issues? I inspected the grounds and connections when I had the engine out, all seemed well..

69CRUZR · 01-25-2012, 10:13 PM

just to double-check...I was supposed to check the volts in AC Voltage correct? Thats what I read on here...

TwinsofMLB · 01-30-2012, 07:13 AM

If you're checking AFTER the regulator, DC volts. There's a rectifier in there. I guess I misread some of that, because yes, that does sound like a bad regulator.

neversinksmith · 11-06-2012, 07:28 AM

wondering if you figured out your issue. i have a similar one. ive got a 2000 polaris xc500. just picked it up a mth or so ago. when i fire her up the lights are very dim and the yellow wires and the black rubber plug that the voltage regulator plugs into get very hot. while this initial few minute warm up period is happening, i noticed that the light on the volt reg is NOT glowing. after a few mins, the lights get bright, the glow returns to the volt reg, and the wires begin to cool down. ive read lots of info on the forum but cant find an answer. i have cleaned brushed sanded down metal mounting plate on volt reg, and sanded down the sled frame literally down to bare metal. around 13.5 reading on volt meter. CAN ANYONE HELP???