2002 Suzuki Eiger LT-A400F Low voltage

Ok on top of my brake issue I am also having a low voltage issue.
The atv runs great it's just the lights/fan do not work and the battery does not charge. (Have to start with recoil start).
I tested the wires that are coming from the stator for the charging part (3 black wires) and they all range from 1.3 volts to 1.8 volts it gets higher as the engine goes slower and the lights get brighter as you are killing the engine. Now when I idle it a little higher it stays steady at 1.18 volts. What is going on here is the stator bad or what else can I do for diagnosis. Thanks

I would say that if it is really putting out less than 2volts, the Stator is bad, it should be putting out more voltage than that, are you measuring the voltage in AC? I also don't think it would run if the stator is putting out less than 2volts. Since the ATV runs ok, I would think that it is more likely that the problem is the regulator/rectifier, or just a bad battery and/or battery cables.

Ya the voltage is coming directly from the wires inside the engine, right at the first set of connectors, so that is before any voltage regulator or rectifier. I was measuring in DC volts, should it be AC? I remember reading somewhere that there are two parts to the stator one for running the ATV and one for the charging system,lights, etc. I have tried a fresh battery and it will start normally and the lights will work until the battery runs out and dies then nothing works again. So the battery and cables seem good it just is not getting charged. Is there a way to test the regulator/rectifier, and do you possibly know where it is/ what it looks like? Thanks

The stator puts out AC current, the regulator/rectifier, is what regulates the voltage level, and the rectifier part turns the AC into DC current so it can be used by the ATV's 12 volt system. All of the output is in AC volts one output goes to the rectifier, one goes to the CDI which has its own inverter and capacitor to convert the AC voltage into a high output DC charge that is sent to the coil when the pulsar coil tells the CDI to fire.

Ok ya I tested it in AV and it hovered around 2.1 volts? Does that sound any better or no?

No, I would think somewhere around 50v would be normal. I would say that it is safe to assume that the stator is bad, but I would figure out the specs for the direct resistance and continuity tests and do perform those before you decide to replace it. I only say that because I don't want to tell you to get a new stator and have the problem be elsewhere. I also find it wierd that the machine will run off a stator that puts out voltage that low. I would recommend a repair manual, all of the tests for electrical components are in there, and there will be a troubleshooting guide that may offer some possibilities that I am overlooking.

Originally Posted by DirtDemon No, I would think somewhere around 50v would be normal. I would say that it is safe to assume that the stator is bad, but I would figure out the specs for the direct resistance and continuity tests and do perform those before you decide to replace it. I only say that because I don't want to tell you to get a new stator and have the problem be elsewhere. I also find it wierd that the machine will run off a stator that puts out voltage that low. I would recommend a repair manual, all of the tests for electrical components are in there, and there will be a troubleshooting guide that may offer some possibilities that I am overlooking.

Ya thats what I read somewhere so I went ahead and bought one off of Ebay for $150, has 1 year warranty pretty good deal. I should get it soon I already got the thing apart and the old one out so as soon as it comes in I'll put it in and let you know. Thanks for your time and info.

Anytime my friend, let us know how it goes.

Well now im lost I replaced the stator and now at idle I'm getting 9.6 - 11.2 volts and when i increase the engine speed it goes down to 3.2 and just hovers there. So it seems like it has gotten better but what else could be causing the low voltage. Im starting to think it is the regulator/rectifier since the voltage jumps so much, but could it also be the magneto(rotor part)?

have you check the fly wheel
the old style fly wheel has glued on magnet and they get loose
it works at low rpm but at high rpm the magnets don't turn
this is a common brolem for suzuki atv and motorcyles that use glue on magnet