Hello, I have a very strange issue going on. I have a 2007 Sportsman 500 X2 EFI.
Problem: The ATV was not charging my battery. I measured the volts from the battery while the ATV was off, on at ideal, and on at 3,000 RPMs and the battery voltage never changed (12.4 volts). I immediately jumped to the conclusion that it was a problem with the regulator/rectifier (located within the PDM) because I had issues with the PDM in the past. However, I noticed that on the console where it shows the RPMs that it was reading a constant 0 while the ATV was on. The RPM number never changed. After doing some reading and research I found that this often due to a Stator issue.
So I went to the manual and got all the info I need to test the stator. Here is where my problem comes into play. I unhooked the stator connector. Powered on the ATV and began to take readings. As per the manual's instructions I separately measured the voltage across each “leg” of the stator by connecting the meter leads to the wires leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to Y3). Each one came back as 0.00 on the meter. So I figured I found my issue, a bad stator... BUT i then plugged the Stator back in and powered up the ATV and BOOM suddenly the RPMs started reading on the gauge and the battery was getting charged. I held the engine at a steady 3,000 RPMs and took battery reading and it was at around 14.2 steady. Then with the motor off it was back at a 12.4.
So all signs show that the issue was resolved by simply unplugging and plugging the stator back in. So I decided to unhook it again and take another meter reading with the ATV on, but again each leg reads at 0.00. I don't understand. How can the legs show no readings yet when I plug it back in it appears to be working and charging the battery now. I watched several videos on how to test the stator and I know my meter is on the correct settings. I don't know if I am doing something wrong with my test or if its something else. I made sure my meter was touching the metal pieces on the connector legs, but still 0.00. I will attached a pic of what the stator connector looks like.
I know most would say that if its working then ride away and forget about it, but I dont want to get stranded somewhere if the stator is the actual problem. I dont want to just assume its bad since a replacement part is over $500 so I would love to be 100% certain its the stator and not a wiring or PDM issue. Please help!! Thank you for the your time.
