QuestionQUESTION: Hello, I have a 2003 Polaris Trailblazer 400. The electric start did not work on a trip recently. Pull starts easily on 1st try every time. Purchased a new battery and checked the voltage. It is only getting 12.5 volts while running. Can you give me ideas what to check and how? i.e. how to check a stator etc. Thank you.
ANSWER: Mike. It sounds like the charging system may be working just not charging enough voltage for the demand needed. Check the starter first. Because of it location on the bottom side it get a lot of heat and crap in it and can take them out. We have 2 of them and a 250 and we seem to go through a lot of stater repairs. Check the brushes first if this wont help the get a new starter. Also test the charging system idle and at a higer rpm then check it with the lights on see if it can keep up. The stator usually has three wires of the same color yellow or white and can be tested with an ohm meter to see if one of the leads is grounded making it weak when it comes to charging.
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QUESTION: Thanks for the reply. I forgot to mention that when I installed the new battery, the electric start works like a champ. But after a day of riding trails, it won't charge the battery back up. So yes, it is not maintaining a high enough level. I previously also checked voltage while at idle, while at rev and with the lights on but there wasn't a significant difference that I noticed. Therefore since the starter is good, does that only leave the stator to be checked? If so, can you provide me with some steps of how to change one out if need be. Unfortunately, I do not have a manual for this machine. And if there is another thing it could be, like a regulator, not sure if there even is one. I appreciate your info.
AnswerMike, Some of the Polaris models had a update kit for the charging system. It consisted of a flywheel,stator,voltage regulator,wire harness and installation instructions,I dont know if this is one of them. It does have a voltage regulator to change the AC charge from the stator to a useable DC voltage. There is usually 3 wire that come from the stator all the same color some yellow and some white. Try an ohm meter and disconnect the connector from the stator to the regulator and test for continuity between each leg. Also check to see if any one of the wires has continuity to ground,it should'nt have. See if you can get a Clymer manual because its pretty easy to read and use and will come in handy for testing procedures and other repairs.
