The high temperature of the stator wire and connector may mean you are using a parallel type regulator instead of a series one. Polaris Sportsman 4WD has the original serial type regulator. These regulators draw only the consumption current from the stator. Parallel types of regulators draw maximum current from the stator and then exactly what happened to you happens. Check what type of regulator is in the original. If you put a parallel type regulator, then you have significantly increased the probability of burning the stator.
@@3FHVSP I am not an electrical engineer that is why I did a lot of research on the system. As stated in the video with the help of a great Polaris parts man hooked me up with a voltage regulator from Ricks electric in New York. He must have gotten it right as I did both my 2015 RZR’s back in 2018 and all has been fine ever since. I really feel relocating regulator to the firewall on a ceramic heat sink and using the 10 gauge high temperature wire and eliminating the jumper with 16 gauge wire Polaris put in the circuit surely helped over 5 years since I did this to both machines and no charging problems but best of all no melted wires and no close calls of fire. Just wish someone like you would have been working for Polaris when I called them when I was having all the problems. Thank you for watching.
You are welcome drove me crazy till I got it figured out, been riding the heck out of both machines this summer, and all is still working just fine. Was well worth the money time and effort.
Having the same issues, failure after failure. Where did you order the 3 pin connectors? I had to buck off the stator plug and buttsplice it to get home because the plug melted and almost caught fire.
I had a piece of scrap ceramic laying around and cut it in half and drilled mounting holes. I am a hoarder so when I saw the scrap piece I got the bright idea to use it for a heat sink.
@@rzrpap thanks so much. I didn't have that problem, but I definitely have Voltage problems and I'm changing all the wiring which I was unaware is since because it's underneath so from the stater to the voltage regulator. I'm doing new wiring and I'm also relocating
2016 570 ranger. My problem turned out to be a bad ground. Everything is grounded under the fuse box under the drivers seat. Factory job is terrible, too many wires in each ring lug, poor crimp, and ground stud and frame are painted. My son could have done better when he was in the 5th grade.
@@stlreaper8392 Polaris definitely didn’t think things try putting the rectifier in front of the left rear wheel. I was amazed when I called Polaris they didn’t want to help had to figure it out on my own with the help of a great Polaris parts man. No trouble at all since I installed the Ricks voltage regulator built the new harness and relocated to front of machine on the firewall.
lucky man ive put 3 new regulators new stator checked almost all wires and i still have no charge on my rzr 800 really sucks just did a full rebulid also hasnt seen the trails but on time and smoked a bottom end beacuse we had no oil pressure crazy these machines are good but a pain to work on the charging system
Is the flywheel bad, see mine had the magnets falling out cutting the stator. The wires were grounding out at the stator causing wires to melt on the voltage reg and have overcharging issues.
Wow My wife and had 2008, and a 2011 rzr 800 and never had one issue. When we got the two 900 rzr all we had was voltage regulator issues until we upgraded to a Ricks hot shot regulator moved it to the firewall required the whole system with high temperature wire. Does it charge for a time after you install the new regulators? I know the regulators I was getting came from China they were junk. Did you check with Rick electric?
god bless ya lad !!
The high temperature of the stator wire and connector may mean you are using a parallel type regulator instead of a series one. Polaris Sportsman 4WD has the original serial type regulator. These regulators draw only the consumption current from the stator. Parallel types of regulators draw maximum current from the stator and then exactly what happened to you happens.
Check what type of regulator is in the original. If you put a parallel type regulator, then you have significantly increased the probability of burning the stator.
@@3FHVSP I am not an electrical engineer that is why I did a lot of research on the system. As stated in the video with the help of a great Polaris parts man hooked me up with a voltage regulator from Ricks electric in New York. He must have gotten it right as I did both my 2015 RZR’s back in 2018 and all has been fine ever since. I really feel relocating regulator to the firewall on a ceramic heat sink and using the 10 gauge high temperature wire and eliminating the jumper with 16 gauge wire Polaris put in the circuit surely helped over 5 years since I did this to both machines and no charging problems but best of all no melted wires and no close calls of fire. Just wish someone like you would have been working for Polaris when I called them when I was having all the problems. Thank you for watching.
Yep, classic polaris. My ace was doing the same thing and or killing batteries annually.
Thanks for the vid!
You are welcome drove me crazy till I got it figured out, been riding the heck out of both machines this summer, and all is still working just fine. Was well worth the money time and effort.
Having the same issues, failure after failure. Where did you order the 3 pin connectors? I had to buck off the stator plug and buttsplice it to get home because the plug melted and almost caught fire.
Kory, got the metro- pac at cycle terminal shop@cycleterminal.com 732-281-7657
Also get the high temperature 10 gauge wire.
where did u find the heat shield?
I had a piece of scrap ceramic laying around and cut it in half and drilled mounting holes. I am a hoarder so when I saw the scrap piece I got the bright idea to use it for a heat sink.
@@rzrpap hahaha… me too !
i’ll keep looking!
thx again !
Does the 630 metric pack directly plug in to the voltage regulator? I have the same problems
Yes it does. My problem all the connectors were melted and had to be replaced. Another year since I did this to our RZR’s and no problems at all.
@@rzrpap thanks so much. I didn't have that problem, but I definitely have Voltage problems and I'm changing all the wiring which I was unaware is since because it's underneath so from the stater to the voltage regulator. I'm doing new wiring and I'm also relocating
@@garychios Good job that way you know it will be done right. Glad video helped you.
2016 570 ranger. My problem turned out to be a bad ground. Everything is grounded under the fuse box under the drivers seat. Factory job is terrible, too many wires in each ring lug, poor crimp, and ground stud and frame are painted. My son could have done better when he was in the 5th grade.
Hi,I got RZR 800 S 2013
Burn wires before get voltage regulador,somebody have dame problem,need help,please.
Bought a 2016 rxr xp4 1000 turbo with 300 miles friday. Second day of owning it and the stator wires melted. Junk
@@stlreaper8392 Polaris definitely didn’t think things try putting the rectifier in front of the left rear wheel. I was amazed when I called Polaris they didn’t want to help had to figure it out on my own with the help of a great Polaris parts man. No trouble at all since I installed the Ricks voltage regulator built the new harness and relocated to front of machine on the firewall.
Does it matter why the yellow go back because my melted off and idk what why they go
Yes the yellow wires go to the stator inside the engine
Yes the three yellow wires go to the stator inside the engine
lucky man ive put 3 new regulators new stator checked almost all wires and i still have no charge on my rzr 800 really sucks just did a full rebulid also hasnt seen the trails but on time and smoked a bottom end beacuse we had no oil pressure crazy these machines are good but a pain to work on the charging system
Is the flywheel bad, see mine had the magnets falling out cutting the stator. The wires were grounding out at the stator causing wires to melt on the voltage reg and have overcharging issues.
its the fusible on the red wire off of the Output of the Voltage Regulator. It goes to the solenoid underneath. Do a continuity test
@@garychios I figured it out it was a few negitive wires hiding under
got another regulator on the way
Wow My wife and had 2008, and a 2011 rzr 800 and never had one issue. When we got the two 900 rzr all we had was voltage regulator issues until we upgraded to a Ricks hot shot regulator moved it to the firewall required the whole system with high temperature wire. Does it charge for a time after you install the new regulators? I know the regulators I was getting came from China they were junk. Did you check with Rick electric?