First Name: Tommy
My RZR: '08 800 RZR
Join Date: Jun 2014
Location: Chesterfield, Va
Feedback Score: 0 reviews
Re: 2008, voltage regulator relocation issues?
The connectors are either WeatherPack or Metripack (I forget which one right now), and can be purchased a lot of places. Technically, they use a specialized crimper for the terminals, but unless you do a lot of wiring, they aren't worth the price. You can easily crimp them with needle nose pliers, if you take your time.
If you have 20, 50, 60 volts you're checking the AC wires coming from the stator, and that's about right. But remember that only comes out to about 41 amps of usable current, at full rpm's.
The stator wires come out of the stator cover, and the connection is basically under the engine. It was easiest for me to access it by removing the skid plate. I have seen a TON of charging issues from that plug either being damaged, or full of mud/water.
Also, on the battery side of the starter solenoid, there is a "tree" of 3 wires on a single connector. That "tree" of wires are fusible links.......1 for the main power wire into your fuse block, and the other 2 are eventually connected to the 2 red wires coming off the voltage regulator. That's how the battery gets charged. I have seen all sorts of weird charging issues, and various other electrical glitches caused by one of the fusible links shorting out from the VR. You still have 1, but not getting full power because the other is blown. It's like chasing your tail trying to figure out what's wrong because unless you KNOW they are fusible links, they like like normal wires, and you never think to check them.
If you need an 08 service manual, PM me your email address, and I can send you one.
08 RZR 800- SATV +6 High Clearance LT kit, Rhino axles, 900 XP shocks, 900XP front bearing carriers, dual core radiator, QSC clutch, 30" Carnivores/STI HD6 wheels, 3500lb Polaris winch, LED headlights, 30" lightbar, 7" LED driving lights, EMP 1/2 windshield, Air box relocation w/ custom snorkels, SATV EPS, CycleWorx 65amp VR, BoeschBuilt parking brake, dual Venom whips