Polaris 2006 switchback 600 electrical issue

[Natethegr8]

I have a 2006 600 switchback in which I intermittently will lose complete electrical but will the motor and sled will operate perfectly fine, checked all connections and no rubbed through wires have already replaced the hand warmers and voltage regulator and still having issues, checked my chassis ground and cleaned and sometimes runs with electrical power and other times just lose all electrical, is there a chassis relay or any relays I could check and could the stator be causing this even though the engine runs perfectly fine?

 

[850Switchback]

Aftermarket regulator or factory? There are separate circuits off the stator for critical (ignition) and non-critical (lights & accessories) loads. That's why it runs fine and could possibly be one of the stator circuits failing.
Intermittent issues suck to diagnose.

 

[Natethegr8]

Aftermarket regulator or factory? There are separate circuits off the stator for critical (ignition) and non-critical (lights & accessories) loads. That's why it runs fine and could possibly be one of the stator circuits failing.
Intermittent issues suck to diagnose.

I would say this may be it but this is a cfi sled and this is an spi voltage regulator because Polaris didn't have the voltage regulator in stock as they made a relocation kit for it

 

[850Switchback]

I haven't heard any good things about aftermarket regulators, hell even the factory struggles with them as you've seen by the redesign.
That being said, you really need to hunt down a wiring diagram or get a service manual at this point. The newer CFI's have the stator split into dedicated coils isolating the circuits to separately feed the ECM, regulated AC & regulated DC circuits. Not sure how the earlier ones are setup.
My guess is still the regulator but you really need to check the resistance at the stator coils on the circuit feeding the AC side of the voltage regulator to make sure it isn't going bad. That regulated AC feeds the headlight and warmers.