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Discussion Starter · #1 ·
Ok guys, I am really at a deadend.....Long story:
Last fall battery quit charging. Replaced the VR. Still not charging or holding charge, so I bought an Odyssey battery $185. Voltage regulator got extremely hot and buned the floor. I though I had just gotten a bad VR, so I replaced it. Went on another trip and the exact same thing happened. Unplugged and made it back by the skin of my teeth to camp. Got to be a passenger for the rest of the trip, which really sucked. The Polaris dealer thought positively that it was the stator, so bought both a stator and a VR. I now replaced the stator and VR 3 days ago. After running around the block for 2 minutes, I came back to check, and the VR is extremely hot again and the wires coming out of the stator are too hot to touch.
Battery after sitting overnight reads 12.55v
10.8 at the startup hit
14.5 immediately after startup at the battery at an idle
14.4-14.5 at 3000-5000rpm with NO jump during rev or decline from 5000-1200
unhooked the red and black wires from VR to battery and they test at 14.3 up to 14.78 revving to 5000rpm.
hooked back up to battery and again 14.55ish at idle-5000rpm.
unplugged harness from stator to VR and tested all 3 wires at [email protected] // [email protected] // [email protected]
checked ohms on stator at 1.2
pulled the ground wire from frame, wire brushed both the frame to bare metal and connectors are polished shiny bare metal.
I even ran another ground from the battery to the frame in addition (temporarily) and continues.
Battery checked out perfect and borrowed a battery from a buddy, and the exact same scenarios continue to happen.
I am at a complete loss.
Why do I seem to be getting an overcharge and losing VRs? When I changed the stator, all looked normal in there, and I saw just a tiny bit of oil in the stator cover. reading in other places, this is not abnormal, but it seemed odd to me.
Please let me know your ideas, I am at a real loss at this point. This charging system is pretty dang basic and it really has me baffled
 

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I don't know what to tell you. But when I had a 2015 trail before the recall I noticed the voltage dropping headed back to camp. When we got there we were dragging the voltage regulator by the wires. Reattached it with fender washers and extra washers for spacers because all the plastic fins on the body had melted off. Jumped it because the battery was dead. Never had another problem. Probably another thousand miles had the recall done and no problems after that either. Good luck. I knew there was a problem with these 2015 voltage regulators before we had the melt down so I always starred at the volt reading on the dash. I never saw it go above 13.8 volts.
 

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Discussion Starter · #6 ·
checked the +/- cables and like brand new. Not positive how to check amp draw.but pulled positive cable and put the meter in line and 0.00.
getting my butt kicked with this thing!!!
ran it at 3000rpm for 60 seconds and the stator wires were too hot to touch and then after 90-120 the VR was abnormally hot....

damn it Jim........
I don't see any wires with any abnormal wear or breaks.
again tonight 14.5-14.66 whether at idle or 5500rpm. no jump or drop.

I cannot afford to keep dumping cash into VRs!!!
 

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Discussion Starter · #7 ·
update*****
Replaced VR and same result (again)
Replaced the stator with RM Stator....wires hot as hell, especially on the stator side.
everything inside seemed clean and normal. no scarring/etc.
there is a bit of oil inside the case, but I am understanding that it is normal.
Bought RM Stator VR to match up with the stator.......wires hot as hell after 60 seconds
tested out both the stator and BOTH VR. all tested good and equally.
tried the RM stator with both VRs separately, and again, wires hot hot hot.........
replaced the RM stator back to the OEM stator and tested/ran with both VRs and each time, the wires got hot as hell and eventually, the VR unit itself. too hot to touch!! AGAIN
I scrubbed all of the ground wires and frame at attachment.. all good
I put a jumper cable from the motor to the - post on the battery, and STILL the stator wires got too hot to touch!
what the hell is going on? seriously ready to take this thing to the dealer to trade off for a motorcycle!!!!
UGHHHHHH any thoughts?
 

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What do you have for accessaries? LED lights, stereo and etc. Maybe you are really pulling alot of juice from the charging system.
 

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These lower amp VR will get hot enough to burn you. They are not big enough for these RZRs when you have a higher amp load than stock. Add a 30" light bar to your system and now you are pulling 9 to 10 more amps.

Our 65 amp VR will get warm but not burn you. So since ours are not maxed out all the time, they will not get hot. They are also 50% larger with BIG cooling fins. It isn't necessary to move them from the stock location either.
 

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Yes there are others with the problem. We have a 65 amp VR with a replacement harness to eliminate using the stock part of the harness for the VR. It has heavy gauge wires to go to engine and the battery. We sell the 65 amp VR and harness for $360 shipped.

https://www.hawkengineering.com/vr.html
 

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Discussion Starter · #19 ·
sorry for the late update,but 2 weeks ago I ordered the Hawk VR. HUGE shout out to Jason and Hawk!!! problem solved
I cannot believe it! absolute HUGE thank you to Jason and the team!! if you have this trouble............spend th $360 and don't waste your money on other crap!!!!! thank YOU Jason!
 
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