2004 Polaris Touring Service Manual, Page 305Get this manual
ELECTRICAL Short Circuit Current (AC Amp Test)
12345Turn multitester dial to AConnect red lead to 10A terminalConnect black lead to Com () meter terminalDisconnect lightingcharge coil wires from systemConnect meter leads to coil wires leading to stator coilsStart and idle engineReadings should be above ampsRefer to Amps AC on page 9.2
Regulated Voltage
1Connect the alternator to main harness connector2Insert one of the tester leads along the side of the yellow regulator wire connector between the insulation and the terminal3Ground the other tester lead4Start engine and observe headlight outputIncrease engine RPMIf the headlights seem dim above 3500 RPM, let the engine return to idle and disconnect the yellow wire from the regulatorCarefully observe the voltage readingDo not allow voltage to increase above 14.0 volts5Slowly increase RPMVoltage above 12 volts at 25003000 and bright headlight, indicates good lighting coilVoltage below 10 volts at 3000 indicates excessive system loads, poor flywheel magnets, lighting coil problems, or wires harness problemsCheck for partially grounded (shorted) yellow wire6Reconnect the yellow regulator wire and increase the RPMIf the headlight was bright with the regulator disconnected and dim when connected at the same RPM, the regulator or regulator ground is at fault