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Flipper Tiffany Roper Jones

Polaris 500 sportsman give it gas stalls

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So with everything hooked up, what’s your DC voltage at the battery and where I am going with that is if at idle it’s 12.7 and when you give it gas it goes down to 7, I could see that causing it to cut off as that may not be enough juice for the coil to function. And obviously if you only have 12.7 at idle with everything hooked up you clearly have a stator/regulator issue. I’d probably go with a Ricky Stator replacement ignition system.

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Ok heres how I tested it I fired up the quad it was idling the voltage regulator up front tested 2 primary stator wires right there 18.7 so plugged those back in switch meter to dc tested that 12.6 well that was working right so I took stator wires back off now its 22.2 ac so I revved it up a little it went to 40v ac that's phase to phase

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But the only thing that cares about the AC voltage is the regulator. The entire rest of the machine is only concerned with the DC. So the entire rest of the machine, including the ignition circuit, only cares about DC. The two components before you have DC are that stator and rectifier/regulator and those would be considered either good or no good and as a general rule their status will be based on the DC voltage. If you don’t have 13.6 (or so) while running at the battery you replace either or both of those components. In my experience, the stator is pretty typical. You usually find one of the coils going to ground and its bad. Period. I have absolutely seen stators ohm from lead to lead out of spec and it ran fine. Maybe it would charge a little stronger or weaker than one in spec but it would not keep the machine from running. So for that reason and also the fact that the solid state rectifier’s job is to manage the AC voltage, I have never cared about the AC voltage. If you replace the stator with a known good setup (with verified correct flywheel) and you still have either nothing over 12.6v or you have something high like 15vdc+ then you replace the rectifier. I personally feel you will drive yourself nuts chasing variances in AC voltage. (Been there done that and ultimately the solution was always to replace the stator or regulator). Also there is one other variable and that is the Polaris machines used to use this stupid box called a SureFire box. I just can’t remember if the 500’s used them. For sure on the 325’s and 330’s. If you have one of those sure fire boxes, they are notorious problem devices.

Yeah that’s the old style flywheel and what I would expect on a 99. That stator almost looks aftermarket. Any brand on it?

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If it was me I’d be ordering a new Ricky Stator just to take it out of the loop. Just make sure the stator is specific to your year. That one that is in there absolutely looks aftermarket. I just looked on eBay and as I expected the factory ones do t look like that. Looks like China brand. I mean I think you are having to fix someone else’s cheap ass approach.

Edited by BuggyMasters

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That may be enough (obviously) to keep it running at idle but under load it might not fly.

ground is through the mount to the engine. Doesn’t matter if you have battery or not.

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Yea but has to be created somewhere ground just dont come out of thin air especially for dc current now I'm a master electrician of ac and dc I no a ground just cant appear pole wires are connected to ground by earth ground which is just the neutral but ac is coming from generator in the bike then has a wire going to ground inside the stator that has to ground the one leg of the stator to create a ground to the quad 

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That’s what I mean is it’s gotta come from somewhere in order for the path to exist. I am assuming the stator or rectifier provides it or something, I mean all four wheelers will run without a battery so they are getting it from something. Never really researched the details of from where.

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Wow just got in from working on my project bike you guys covered a lot. Great topic discussion. So I’m assuming your going to order a new stator as discussed earlier and I think that’s going to solve this erratic voltage problem. We see a lot of people asking about wiring in an aftermarket stator that does not match up like an oem part. 

Hopefully this will solve your problem. 

Nice work so far and @BuggyMasters great input!!!!

Keep us posted! 

 

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Theres a wire that bolts to the bike from the stator almost is cut through from the flywheel I'm buying a new stator no matter what but has to get a ground from some where in look. Fly wheel almost cut it through but when I first fire it up with a new voltage regulator today perfect 14.8v on dc side soon as I revved it up just a little stalled now I cant even get 7v on dc side so I'm getting a new stator screw all this and voltage regulator and going from there with American parts this is bs

20190907_190524.jpg

20190907_190520.jpg

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Yeah man sounds like that stator may be wreaking havoc. Will be watching the progress. You’ll be happy when this thing is done!!

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I'll be relieved actually I swear I'm really good at working on bikes but I have to admit this is one that's gonna get the best of me or it will work right one of the 2 I will keep you guys informed 

Everytime I look online there all under $50 except for Ricky stator why

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Why is because Ricky stators are well built. They make stators that are equivalent to oem stators.  You get what you pay for however I have used Caltric and have had luck.  Plugged right in and worked great.  Never used or ordered one for a 500 like yours but I did use one on my old Polaris Phoenix and worked without any issues.   

I believe you 100% when you say you know what your doing when it comes to doing this work. We always get that one problem child that will drive you bat shit crazy!! So see this pain in the ass through and move it along. 

Keep us posted please and @JacobSlabach you also through me for a loop with that color thing ??? 

 

 

 

 

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Is the sportsman same as magnum I was just going through all the plastics guy I bought it from said it was a sportsman so I never checked but plastic says magnum 500 everything I have bought has been for a sportsman I hope the the same anyone have a 99 magnum 500 manual by chance 

That's on the board of dumbass rookie mistakes holy cow 

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I  didn't  find a service manual  for the  Magnum , but here is a wiring diagram for it.

 

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