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2003 550 Trail Touring

kev_alaska

New Member
Messages
7
Age
64
Location
Willow
Website
eaglequestalaska.com
Country
USA
Years Snowmobiling
40
Snowmobile
Skidoo SWT, Summit X
electric start model. electrical problems with this one. The book calls for a 4010794 voltage regulator (replaces the 4010355). the electrical harness on this one has only a two prong plug. i replaced the VR and all the bulbs with an aftermarket VR. No electric start, lights and handwarmers work fine. ordered the Polaris regulator...The 4010794 has three wires. the existing VR has only two wires, red and yellow...What am i missing?
 
What color wires are on the new reg?

The yellow wire is unregulated "AC" voltage into the regulator from the stator, red wire is 12 volt "DC" out to charge the battery.

The way those regulators work is they ground off any excess voltage (anything over about 13 volts) so no need for a voltage "out" wire.

Is the third wire brown?
 
The brown wire is a ground but you really don't need it. The mounting bolts of the regulator serve as the ground also.

I usually cut the brown wire and crimp an eyelet on the end. Put it on one of your mounting bolts for the regulator.

Like I said in the earlier post, the regulator grounds off any excess voltage above 13 volts, give or take. Never hurts to have an extra ground.
 
that is about the best explanation of a VR that i have ever seen. replaced the existing one with the 794, added the ground, works perfectly. Thanks.....
the old VR only had two wires, but instead of red/yellow, it was yellow/brown......?? obviously the wrong application.
 
Regulators with yellow and brown wires are a regulator only. Yellow is unregulated power from the stator, brown is a ground.

Regulators with yellow, brown and red wires are a combination regulator/rectifier. All of the power from the stator is "AC" voltage. Your battery is "DC" voltage. The red wire is power coming out of the regulator that is converted to "DC" voltage and charges the battery only. (can't charge a "DC" battery with "AC" voltage) Yellow and brown are the same as above.

Regulators with no brown wire are grounded thru the mounting bolts only.
 


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