2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 241Get this manual
ELECTRICAL
CHARGING SYSTEM TESTING FLOW CHART
Whenever charging system problems are suspected, proceed with the following system checkUsing multitester set on D.Cvolts, measure the battery open circuit voltage (See Page 10.19)It should be 12.4 volts or moreIs it? Yes
Meter Setting: DC Volts
Remove the battery and properly serviceReinstall the fully charged battery or fully charged shop battery
With the transmission in neutral, start the engine and increase RPM to between 3000 and 4000Read battery voltage with the multitesterReadings should increase to between 13.0 and 14.6 D.CAre they? No
Meter Setting: DC Amps
Check Key off Current Draw
Perform system Break Even Amperage test outlined on Page 10.16Does charging occur as specified? No Ohm stator wire (YYR) If bad replace, if good, continue with alternator output testMeter Setting: AC Amps