2001 Quadmaster voltage regulator

Mike Johnson · April 15, 2019

Hello Guys, I'm new to the site, but have been reading about all the issues that I to have had with my quad. I have rebuilt the carb a few times, once when I got it a few years ago and again a few weeks ago. Same problem, it cranks fine and idles well but when I take off it stumbles. After looking at the site I saw all the posts about the rectifier/regulator so I grabbed one off eBay which came today. Once I found out where it went I saw that the original one wasn't there so I have no reference however I mounted it and began to connect it but one the plugs doesn't fit. The red/black plug connected fine but the yellow wire plug doesn't, and I don't see any other plugs available. Apparently the guy I bought it from had removed the original regulator and it wasn't with the ATV so I have no idea what it looks like. I will also say that I was surprised that it didn't have a rectifier on it but cranked and ran fine till the stumble. My question is, do those yellow wires have to be hooked up ? And my apologies for the rambling, I'm doing this on a phone and can't see the screen. Hahaha

**Ajmboy** · April 19, 2019

I just added the manual to the downloads section and it contains the wiring diagram

xTraveyx · May 26

His I have a 2000 suzuki quadmaster was running fine one day on the snow to plow, 5hen next day no power to dash, nothing lights up have power to power fuse, traced to the regulator. Power in but not out, does that explain the no lights or pull over start? You can jump silinoid but just turns over. I'm at a loss for this thing.

**Mech** · May 26

Unless the regulator is draining all the battery power, in which case you will be getting flat batterys, then I doubt it's the regulator.

You would I imagine have turned the key off when you stopped it, and if it was running up to that moment, then I'd be suspecting the key switch as the most likely thing to have changed between it running and your now trying to start it. Nothing else should have changed once it's turned off..

I'd check the key switch, and the kill switch first.

xTraveyx · May 26

1 hour ago, Mech said:

Unless the regulator is draining all the battery power, in which case you will be getting flat batterys, then I doubt it's the regulator.

You would I imagine have turned the key off when you stopped it, and if it was running up to that moment, then I'd be suspecting the key switch as the most likely thing to have changed between it running and your now trying to start it. Nothing else should have changed once it's turned off..

I'd check the key switch, and the kill switch first.

I replaced key switch all fuses, battery's fine winch works perfect even now. But I have no power or fire.

**Mech** · May 28

Well wires do break. You need to use either a test light or a volt gauge and trace the wire from battery to fuse to switch, checking power is getting through. Sometimes we can find a broken wire by wriggling them one at a time near their ends where they connect to the metal terminal and they feel too flexible if the wire is broken inside, and if we have the key on at the time, the power might flash on.

When you say you traced the power to the reg, and had power in but none out, do you mean it was running and not charging ?

xTraveyx · May 29

On 5/26/2023 at 4:05 PM, Mech said:

Unless the regulator is draining all the battery power, in which case you will be getting flat batterys, then I doubt it's the regulator.

You would I imagine have turned the key off when you stopped it, and if it was running up to that moment, then I'd be suspecting the key switch as the most likely thing to have changed between it running and your now trying to start it. Nothing else should have changed once it's turned off..

I'd check the key switch, and the kill switch first.

No with the on or off I was getting power past the fuse, past the silinoid to the voltage regulator. I followed my hot wire and nothing after the regulator as seen in the picture.