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Discussion Starter · #1 ·
I've spent hours going through posts to help troubleshoot my battery isn't charging. For the life of me I cannot locate the voltage regulator in this machine, even the parts view doesn't show one. Any help would be appreciated, bottom line is I'm trying to test stator output but ruling out all the parts in the flow... relay is good. Sled works perfect if pull started but runs off the battery. Much thanks.
 

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Discussion Starter · #4 ·
Thanks for the confirmation Daag44... at least I`m not going crazy not finding it as a seperate device. Noboy seems to talk about that so wonder if its specific to that year. So I guess my next step is to remove the stator plug from the ecm and look for 20v coming there on the 6 pin connector. Thanks for your help... trying to get back on the trails by Friday :)
 

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Power Distribution 800 ETEC 2010.5-2012 .

Note everything in the upright rectangle box is in the ECM including the VR and DC-DC converter to step down the 60 Vdc to ~14 Vdc (aka 12 Vdc).

Up until 2012 it had a battery charging relay which was later integrated into the ECM for MY2013 and on. So for your sled I would test the feed side of the starting system relay to see if it is getting any power from the DC-DC converter. As you can see from the diagram, as long as the lights and gauges are getting power, then this confirms the DC-DC converter is working.

Power Distribution 800 ETEC 2010.5-2012 with battery charging relay.jpg
 

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Discussion Starter · #6 ·
Thanks Daag44, I have already taken out the relay and bench tested it and is fine. To your point above all my lights , warmers, visor all work fine when its running so converter should be ok. The parts in the rectangle box are all integrated and sealed? Do you happen to have the steps to test the stator... assume I unplug from that ECM box, 6 pin connector. Can I turn over with the battery or need to pull and do I leave the kill switch off or will it not start anyway with that plug out. Much thanks
 

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Discussion Starter · #7 ·
so... tested the stator and have 20vac on each line. Rersistance test checks out ok also. And I bench tested the relay and it is ok. And as Daag44 mentioned all my lights, heaters and visor etc work fine so relay should be ok? Any further test I can do on the ECM at this point, or is it an ECM change. Anything I can test at the communication tester without a reader? Thanks all.
 

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Skip the relay bench test. Measure the voltage of the current being fed to the relay, and the voltage of the current output side that leads to the battery.

To measure the 60 Vdc circuit you can use the positive post on the capacitor.
 

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Discussion Starter · #9 ·
So I have 60vdc at the cap, on the relay both red/ orange wires have about 15v, the red with white is around 12.3v and the orange has no voltage. Thanks Daag44
 

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So I have 60vdc at the cap, on the relay both red/ orange wires have about 15v, the red with white is around 12.3v and the orange has no voltage. Thanks Daag44
15Vdc on the two Red/Orange wires is perfect. This is the current that is fed to the relay for the switch and the coil.

The Red/White is the output of the coil, so it should show lower voltage as the coil is a draw.

The Orange/White wire is the last one to measure. This is the one I referred to as "the voltage of the current output side that leads to the battery." You want this one to be the same as the 15 Vdc that is being fed into the relay. If not, then the relay is has internal resistance from a bad connection.

You are so close.
 

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Discussion Starter · #11 ·
Super... so are you saying the relay could be bad? Or that wire has a bad source, where does that wire come from? You are so much help.. big thanks
 

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Exactly, I am saying the relay is likely the culprit and possibly the fed wire has a bad source. Two very simple voltage measurements at the relay socket for the Red/Orange feed, and Red/White output will show where the trouble lies.
 

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Discussion Starter · #13 ·
OK, sourced a new relay and off to getthat soon. When you say fed wire you mean the orange wire that i measures no voltage at the relay socket? Do you know where the other end of that wire comes from?

Thanks
 

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My mistake. I just realized that you have already measured no voltage on the Orange/White wire. In other words, you have measured voltage going into the relay (Red/Orange feed), and no voltage going out on the Orange/White.

All your measurements confirm a faulty relay. Well that was easier than I expected.
 

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Discussion Starter · #15 ·
Success.... new relay for $7.50 fixed it. Now have 14v at the battery. I've learned a ton about this sled now (had 2002 prior) sure miss just lifting the hood to look inside. Now I get to re-assemble this machine, should be fun but will be on the trails soon. So much thanks to Daag44 he is a rock star :ride:
 
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