Polaris Magnum ATV Not Charging - How to Troubleshoot and Fix it!

My Polaris Magnum 325 isn't charging the battery any more, see how I troubleshoot and fix the problem.
***Links to products I use, or are seen in the video***
Voltage Regulator: amzn.to/3tbTlI1
Solder Seal Connectors: amzn.to/3Icau8q
PTG Merch project-time-g...
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Project Time Garage
1113 Murfreesboro Rd
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Franklin TN 37064
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[@TheMoparGarage]

Nice work! I worked at a Polaris dealership for 6 years, failed voltage regulators were soooo common on these machines!

[@ProjectTimeGarage]

Fuel pumps and starter bendix too. I've replaced more than a few over the years.

[@hillcountrygarage]

I have a Sportsman 500 H.O. and I'm wondering if it might be the same issue. Thanks for showing this "how-to" video. Very helpful.

[@ProjectTimeGarage]

Good luck, hope it solves your issue.

[@cjschoolcraft2038]

little off topic but....I love that challenger you have back there in the back ground

[@ProjectTimeGarage]

Not off topic at all! We love ALL car/truck/tractor/mathematics/atv/diesel/mechanical content. Wait - not mathematics.

[@cjschoolcraft2038]

@@ProjectTimeGarage lol, I love your videos man..keep it up!

[@notagain1212]

Best clear to the point video I’ve ever seen. I really appreciate it.

[@ProjectTimeGarage]

I appreciate that!

[@BethAnneChavoustie]

that 87 conquest tsi is awesome. my favorite car i ever owned. i dont think i ever saw one with the front ground spoiler not cracked in the corners. Tom

[@ProjectTimeGarage]

Thanks, this one is an 88 Starion. 47000 miles, survivor car. I have a few videos on it. Check out my channel for more.

[@rickeyjohnson4491]

It help me thanks a lot my 1999 Polaris Sportsman 500 isn’t charging so Iam gonna order a voltage regulator. Bike only has 525 miles on it runs great.

[@ProjectTimeGarage]

Glad to help!

[@warrenvalentino5763]

thank you for making this Awesome video!! it realy helped me with my 1995 polaris 425 magnum 2x4. :)

[@ProjectTimeGarage]

Glad I could help!

[@kierenfitzgibbon6056]

Gday mate, thanks for the vid on the battery not charging. I've got the same issue! Can you let me know how the cheap regulator went over time?

[@ProjectTimeGarage]

It's been quite a while now and it's still doing fine. Several hundred hours on the machine now and all good.

[@SlickD217]

I had the same problem with my 97 magnum 425. I got it cheap because it didn’t run “the way most of us do” and none of the lights worked. I got it running and realized that it was charging at almost 19 volts. My guess is that it overcharged to the point that it boiled the battery and actually blew every light bulb on the thing. Good quads but they do have finicky ignition/ charging systems.

[@ProjectTimeGarage]

Not to mention that without a battery it'll blow every single bulb in the thing - including those crazy triangular shaped bulbs in the dash lights.

[@derekis1joedirt]

Pretty straight forward

[@ProjectTimeGarage]

Thanks!

[@mattclark7748]

very informative

[@ProjectTimeGarage]

Thanks man!

[@smileysun9212]

I had Polaris’s & fixed them by getting a Honda. My neighbor is having same problem with his Sportsman 500 with a winch & he took it to a place I recommended. He left them a bad review because they couldn’t fix it. I had a AGM battery in my Honda that lasted 14yrs. I bought the OEM replacement & only lasted half as long. I found out when you purchase a battery get it with the newest manufacturer date. The acid gets weaker for sitting so long. Go by manufacturer date & not by when acid was put in battery. I put in old new battery & why it didn’t last as long.

[@ProjectTimeGarage]

Love the Hondas. I've had a few Polaris machines (and Yamaha, and Honda and Kawasaki and Maico, etc)

[@anthonyt.depoalo5475]

i noticed that wiring was a little different on the replacement regulator, does the brown still get hooked to brown and the black wire to the yellow/brown? or vice versa?

[@ProjectTimeGarage]

I think I wound up running the brown to the Yellow/brown and black to brown. Took me a while to figure it all out.

[@danpowers1361]

Could you get me a picture of how all the wires are supposed to go I got this quad secound hand and can’t figure out what goes where

[@ProjectTimeGarage]

shoot me your email address

[@GForceMonkeys]

Is that a Starion!?

[@ProjectTimeGarage]

Yep, good eye. I have a couple of videos of it on my channel.

[@TenMillimeterSocket]

got any tips on how to test the regulator without a running quad?

[@ProjectTimeGarage]

You can get the Factory Service Manual free online (don't buy one). It goes through all the steps to test the regulator off the quad.

[@he_said1773]

Hey I was wonder would you know anything about the rev limiter?

[@ProjectTimeGarage]

The only thing I *think* I know is that is is part of the CDI/ignition system. So I don't think there's any way to change/disable it without changing parts.

[@amansrights]

Hey bro i have a problem with a 96 sportsman i just bought.. the rectifier is bolted in front of radiator under front rack the wires were cut i need to know where the red wire and brown wire goes to the board? To starter solenoid or to battery please help me my battery is not charging replaced stator all my wiring is good except the 2 wires from rectifier red and brown i hav no idea where to run them to board or where

[@amansrights]

I tried running straight wire to start solenoid but and test with multimeter but volts did not go up when rev engine

[@ProjectTimeGarage]

I have the service manual in pdf format. Send me an e-mail with your address and I'll send it out. [e-mail]

[@trevinjohnson1544]

I have a Polaris magnum 325 2x4 that was sputtering and now it does not start. Can you help me figure it out please?

[@ProjectTimeGarage]

Does it have spark?

[@orlandosalinas1823]

Disclpa I have trail boss 325 it doesn't charge my battery. Check the loading coils and homs one gives me 0.6 and the 0.2 there is already bad stator no

[@trevinjohnson1544]

I just changed the spark plug and it still will not start and run but it looks like it's not getting any fuel. What should I do?

[@trevinjohnson1544]

​@@ProjectTimeGarageI have changed the spark plug but it still doesn't start and run but I noticed that it doesn't have fuel running through the lines

[@trevinjohnson1544]

I've replaced the fuel pump the fuel filter ,hoses, cdi box, the solenoid, and I still don't have any luck I really need some help