Have a 2006 Polaris 500 4x4 EFI that charges at 15 to 16 volts at idle. Will come down to 14.1 at full throttle. Have seen some heat at connector on yellow wire at ecm connector. Possibly stator or what?
Welcome to PRC, RRC! Could be a bad voltage regulator or the ECM isn't giving "good instructions" to the VR, possibly because of a marginal connection. Make sure there isn't any dirt or corrosion on any of the VR, stator, or ECM connections.
That year 2006 I belive has the PCM on the fire wall under the hood mounted on the passenger side. It has the regulator built into it like the XP's did I think. If that is the case the PCM maybe on its way. Pull the upper and lower connections and look for burnt connectors. If they show burning and melting no doubt that will be your issue.
If it's one of the yellow wires from the stator (there should be 3 yellow wires (coming from the stator), it will carry AC voltage from the stator. The PCM/voltage regulator will convert the AC to DC to feed the rest of the electrical system. Might be a good idea to get the service manual; it will contain the test procedures for the stator and VR (and a ton of other info!). Only 10 bucks and an absolute necessity for working on your rig, especially the older ones. 2006 Polaris Ranger 500 4X4 EFI Service Manual PDF Download
As Ken mentioned, the voltage regulator is unfortunately a part of the ECM. Since one of the stator wires are burnt, I would repair it and hope that it fixes the problem. Hopefully it didn't damage the ECM when the wire melted.
I just finished working on a friends 2006 Ranger XP with the very same issue. Another Friend helped repair the harness connection. Bottom plug was melted, terminals (yellow wire) on the PCM were damaged beyond reuse. Had to repair the harness and replace the PCM. Cost was around $300 not including labor. PCM's on 2005-2006 Rangers were a weak link.
Good Friend Al and 2005 Ranger XP Owner Helped with my friend's Harness repair and put this list of parts together you can get from Mouser. It is not a real easy job to repair because of the type of terminals, and connections used. They are Delphi components. Here is the list he put together to repair both the upper and lower harness connections. Hope it helps you with yours.
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