PRC Polaris Ranger Club

deanrowski · Posted: Mon Sep 01, 2008 12:14 pm Post subject: RZR voltage regulator

Here's a pic of my voltage regulator! I was riding this spring and all of a sudden I smelled something burning, The worst kind of course! ELECTRICAL!! I Inspected every piece of wiring on my RZR and found nothing!! Everything seemed to be working ok other than my battery icon would come on every once in a while and when I went into diagnostic mode on my display it showed 11.0v to 11.8!! This was with no accessories on! Well since you cannot be in diag. mode while driving I purchased an inexpensive volt/battery tester at wallyworld so I could actually see what was happening! To my surprise It was registering from 17.8v to 11.0v!! So I kind of pinpionted the prob. to my regulator which had a small bulge on the backside. When I peeled the sealant off this is what I found!! I have installed a new regulator and cooling fan on it and now it stays between 12.6-13.9 all the time!! I am running an optima batt. also. So far so good!! [im

g][/i

mg]
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Dr.RZR

deanrowski · Posted: Mon Sep 01, 2008 12:48 pm Post subject:

PS- I know that this mounting technique for the cooling fan is not approved for use by prc members!! Just in the testing stages to see if it would help!! Also I must be able to remove it for washing! You may also see my patented Dust Deletion Tape Or DDT for short!! that I use to block some of the gaping chasms left behind by POPO!!!
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Dr.RZR

ElecTech · Posted: Mon Sep 01, 2008 12:56 pm Post subject:

On the new '09 RZR's, they moved the regulator to a spot out front for cooling air to flow over it. I think someone has posted also that the wiring is too small running between this unit and the battery. A fan though would do the trick.
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Bruce
Member #2
'05 4X4 Ranger
Rangerware accessories

1 Peter 5:7 Casting all your care on HIM for HE careth for you.

rzrcrzy · Posted: Mon Sep 01, 2008 1:01 pm Post subject:

That gaping hole you taped off was to cool the regulator, or did you do that after the regulator cooked up.
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2008 RZR 05-21-08
2006 Dodge Ram 1500 Hemi
1999 RMK 600
1987 Yamaha Warrior
1980 Honda Odyssey FL250

deanrowski · Posted: Mon Sep 01, 2008 1:06 pm Post subject:

I know you are exactly right!! I taped it up before it burned up but It was 42 degrees when that happend!! Still could have and probably was a contributing factor!! This was all done pre DFR Cyclone when all I was worried about was STOPPING as much dust as possible!!!
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Dr.RZR

martymoe · Posted: Mon Sep 01, 2008 10:54 pm Post subject:

as we were talking about earlier, the reason the fan makes it work is because the voltage regulator gets hot and shuts down.. the stator makes plenty of power, but the voltage regulator doesnt get enough air..
i noticed on the 09's that they moved the voltage regulator up front (in front of the radiator) that seemed like a good solution so i moved mine up there.. that is the fix.. i took it to the dunes over the weekend, and i'm able to run 4x4, all my top lights, my headlights, my backup lights, stereo and gps at the same time (while moving) and the voltage was at 13.8 and building..
i had 0 problems with the flashy low battery dash or even problems engaging 4wd like i did before.. this is the fix..

another weakness in this was that the stock harness's wire from the regulator is too light and gets hot.. i was dropping more than a volt from the regulator to the battery

in the next few days i will write up the steps to move it.. i would have done it sooner but i wanted to test it on this dune trip.. i did and i'm happy.
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08 Titanium RZR (m² Edition)..
martymoe@martymoe.info

guy48065 · Posted: Tue Sep 02, 2008 12:36 pm Post subject:

Looking forward to it Marty. Good to have guys like you around Wink

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Now a 2-Rzr family!

agentzoey · Posted: Tue Sep 02, 2008 4:04 pm Post subject:

new8812 · Posted: Tue Sep 02, 2008 10:33 pm Post subject:

Me too, thanks in advance Wink

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4500km of pure fun!

martymoe · Posted: Tue Sep 02, 2008 11:56 pm Post subject:

here are the steps.. hope it helps..
(make sure your connections are rock solid or it will defeat the whole purpose)

http://www.extremerzr.com/Tech/TroubleshootingWiki/tabid/701/topic/ELECTRICAL/Default.aspx

if this link doesnt work it's in the electrical section of the troubleshooting wiki on extremerzr.com
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www.extremerzr.com
08 Titanium RZR (m² Edition)..
martymoe@martymoe.info

new8812 · Posted: Wed Sep 03, 2008 5:51 pm Post subject:

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4500km of pure fun!

bagman · Posted: Sat Sep 06, 2008 9:49 pm Post subject:

Deanrowski, you gave me an idea. Along the same lines just mounted different. Should help provide extra cooling.

RGERBER · Posted: Sun Sep 07, 2008 10:59 am Post subject:

I wish someone would make up a harness and set of instructions with pictures and sell them.
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Polaris RZR - build date - 6-15-2007 - Black ITP True Beadlock Wheels with Polished Rings.26"- 6x9x14 front, 6x11x14 Maxxis Bighorn Tires rear, 1.5 adapters - total width in rear of 63" - Gibson exhaust, Factory UTV skid plate,W.E. Shocks, 2" lift, Holtz front bumper, Polaris flares. AEM gauges, HID headlights,

Overcome, Adapt, and Attack.

Sandblaster · Posted: Sun Sep 07, 2008 11:09 am Post subject:

RGERBER · Posted: Sun Sep 07, 2008 11:24 am Post subject:

Yea, that make us the ginnie pigs
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Polaris RZR - build date - 6-15-2007 - Black ITP True Beadlock Wheels with Polished Rings.26"- 6x9x14 front, 6x11x14 Maxxis Bighorn Tires rear, 1.5 adapters - total width in rear of 63" - Gibson exhaust, Factory UTV skid plate,W.E. Shocks, 2" lift, Holtz front bumper, Polaris flares. AEM gauges, HID headlights,

Overcome, Adapt, and Attack.

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