2005 Vector electrical gremlin

[whitexc]

Hey folks, been a member over on the TYforums for years but just joined here as we now have a four stroke in the family. The sled is a 2005 RS Vector, electric start and reverse. We believe the PO knew the stator was bad and brought the sled for us to see with a new battery so all seemed well. Long story short, it was not....battery died as it wasn't charging and the sled quit.

We just finished installing a new RM Stator, blue dot tensioner, copper exhaust donuts and going through everything else while the engine was out, along with a good cleaning. So we get it together, put oil and coolant in and fire it up no problem....purring like a kitten. My bro blipped the throttle the slightest bit to idle the sled down, it quit and is now blowing the 30 amp fuse on the hot side of the starter relay/solenoid by the battery.

I was thinking we did a great job tucking and routing the wiring but something isn't right somewhere. I did a bunch of reading and there is talk of grounding blocks in the wiring harness? I don't think this is our issue but I would like to check them. I also see guys refer to wiring behind the primary clutch....this sled, unless it was completely re-routed by a PO, has no wiring on the clutch side. All wiring comes down the chaincase side of the machine. Without tearing it all apart and checking every plug etc., what should I look at? I would rather pull the engine and tranny from my truck than deal with electrical crap...hate it. Thanks for the help guys/gals.

 

[BigDogrx1]

Ya bought mine 1.5yrs ago, got slicked with bad stator also, installed same R.M. stator only lasted 300 miles, they don't seem to be very good quality, but they are$159. Luckily can change easy.
Electrical sure sounds like grounding somewhere, good luck, post your finding.

 

[hibshman25]

Almost sounds like a voltage spike. If you replace the fuse will it start up and idle again? If so check battery voltage with it idling. Then with meter still hooked to battery rev it up and see what reading is.

 

[whitexc]

Can't even hook the battery up. As soon as we touch the + it blows the fuse. Can anyone post a pic of their solenoid and the wiring.....maybe somehow we got it mixed up.

 

[hibshman25]

If you were able to start the sled initially I doubt you have wires backwards on the solenoid.

 

[whitexc]

Anyone know what plugs are absolutely necessary for the sled to run? My thought is to unplug anything not relevant to the life of the motor and start from there. I did some browsing of the wiring and there is nothing obvious.

The voltage spike thing almost seemed possible....could it have shorted the pcm and now needs replacement possibly? Just spewing of the brain here trying to muster up something. Thanks for the help.

 

[BigDogrx1]

Geez Whitexc I feel your frustration, electrical problem can sure AGE ya quick.
Thing that drives ya crazy is when finally found and fixed it seems like it should have been easier. Too bad you don't have another sled to swap and plug PCM in to eliminate that, Good Luck and please post findings

 

[Redbeard]

Unhook your battery and disconnect all fuses. Take a volt meter and connect it to the positive wire that connects to the battery and the other end to the frame. If there's continuity, you might have a short somewhere. Then you could start plugging all fuses back in one by one to see if your little gremlin shows himself.

You may have to unplug ECU and rectifier also.

This is a shot in the dark, so someone correct me if I'm wrong? ?

 

[BigDogrx1]

Hey northersledder, wish you were closer to me, I got a feedback in my speedo circuit somewhere.
When idleing and hitting throttle without engaging clutch speedo will jump around and doesn't work when ridding, pod is good and new speed sensor, just don't understand electrical much.

 

[Redbeard]

Hey northersledder, wish you were closer to me, I got a feedback in my speedo circuit somewhere.
When idleing and hitting throttle without engaging clutch speedo will jump around and doesn't work when ridding, pod is good and new speed sensor, just don't understand electrical much.

Wish I could help you. You just have to begin a process of elimination some where; tracing wires, bypassing etc.

I'd start with tracing your wiring and/or verify previous owner didn't perform a scab job.

 

[whitexc]

Well, by process of elimination, we think the voltage rectifier/regulator seems to be shorted internally. With most connections undone, when we plug the bottom plug, which appears to be the rectified/regulated outlet on the voltage regulator the fuse pops. Has anyone out there seen a regulator short like this or do we have another issue?

 

[hibshman25]

leave stator plugged in to regulator and see if you can measure a voltage on output plug of regulator with machine running.

 

[grizztracks]

Yes, the rectifier can fail short circuited. the diodes that make up the rectifier circuit usually fail shorted. If the fuse is blowing with the battery hooked up and the red wire to the rectifier is not shorted then the rectifier is most likely shorted. You can check continuity to ground on the rectifier's red wire. A shorted rectifier can also damage the stator.

What is your location in NY?

 

[whitexc]

Thanks guys. Hopefully the regulator didn't take out the new stator, that would stink. I am almost wondering if the regulator wasn't our primary issue to begin with but I could not get a solid result from ohming the original stator, plus the chain tensioner deal so...it got replaced. I found what appears to be a decent price on a OEM regulator so I ordered that up and will see how things go.

Grizz, we are in the Lockport area, Niagara county. I updated my profile as well.

 

[grizztracks]

If you continue to have issues I'm not far away.