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About a month ago I purchased a 2006 700 EFI. Its worked well, with a few problems.

The first problem was that the battery did not seem to be charging when the machine was running. I would leave it on a charger but after a few days (running it every day), it would be nearly depleted. I would intermittently get a "VOLT" error on the panel as well.

These problems sound like an issue with the voltage regulator, however, I never got around to doing some tests with the voltmeter, because a few days ago, the machine quit while running. Everything was dead.... no lights on the panel.. no nothing. Cannot crank start it. No display.. no nothing.

So I looked at the fuse box and sure enough, the main 30 amp fuse was gone.. so I put in the spare... POW.. it blew as soon as I put it in... (Hadn't even put the key in yet). So I've torn the thing apart looking for a loose wire but so far I haven't found anything that is obvious.

I did unplug the voltage regulator but even with that unplugged, I'm still getting voltage on that 30 amp fuse... even with the key turned off and removed.. I've looked at the wiring harness and I'm having a heck of a time finding the short... Anyone have ANY kind of help?? Thank you very much... first post to this forum!
 

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Quite a few things it can be. Start by downloading a free manual at mymowerparts.com

If I were you, based on your symptoms, I would check the connection on the three heavy white wires coming out of your stator. Usually that plug is melted or corroded beyond repair.
 

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Quite a few things it can be. Start by downloading a free manual at mymowerparts.com

If I were you, based on your symptoms, I would check the connection on the three heavy white wires coming out of your stator. Usually that plug is melted or corroded beyond repair.


Thanks.. I'll download the manual

Because the 30 amp main fuse is blowing even when I unplug the rectifier/regulator... I don't think the problem would be in the stator.. could it??
 

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You may be right-

I guess you can unplug everything and if the fuse still blows, you need to strip the bike and check every inch of the harness.

Check all your grounds first tho
 

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Check the harness where it comes out of the fuse box and goes over the frame.
 

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Discussion Starter #6
Quite a few things it can be. Start by downloading a free manual at mymowerparts.com

If I were you, based on your symptoms, I would check the connection on the three heavy white wires coming out of your stator. Usually that plug is melted or corroded beyond repair.
you are totally right about that plug..its fried....it crumbled when I poked at it..... I don't know if this is what is causing the shorting problem, but I'm guessing it had to do with the battery problem....

how'd you know ??

what happens if i just spliced those wires directly to the stator wires?? Do I need to have a plug there?
 

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Check the harness where it comes out of the fuse box and goes over the frame.

that part appears to be ok... I used a multimeter to test the continuity from the 30 amp fuse lead to the red wire leading in to the voltage regulator/rectifier.. that connection is good.. so I don't think there's a problem in that part of the harness... I'm thinking its the ignition switch at this point... (in addition to my fried plug coming out of the stator)
 

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you are totally right about that plug..its fried....it crumbled when I poked at it..... I don't know if this is what is causing the shorting problem, but I'm guessing it had to do with the battery problem....

how'd you know ??

what happens if i just spliced those wires directly to the stator wires?? Do I need to have a plug there?

I have the same bike. They all have that problem. If you know how to solder (not kind of know, really know) then you can mark the wires so you don't get them mixed up, and solder and heat shrink the wires. If you want to know what it should look like- I'll take a pic tomorrow of a proper solder connection. Hopefully that will solve your problem. If you use crimp splices, your gonna have problems in the future.

That will fix the battery problem. Hopefully it will fix the other one too
 

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the three wires from the stator are not polarity sensitive, just solder them one to one to the wires to the reg, if the stator is not fried it should take care of your charging issue
 

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the three wires from the stator are not polarity sensitive, just solder them one to one to the wires to the reg, if the stator is not fried it should take care of your charging issue
While they are not polarity sensitive, they are phase sensitive.

Do 1 for 1 wire swaps- it's easier that way. Good luck.
 

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Discussion Starter #11 (Edited)
While they are not polarity sensitive, they are phase sensitive.

Do 1 for 1 wire swaps- it's easier that way. Good luck.

I ended up taking the bike to a mechanic, since I don't have the skills or tools to solder those wires... he is having a hard time figuring out which wires to solder to which since the plug basically disintegrated, and the wires are all the same color.

is there any advice or suggestion that I can give to him?... he's a good bike mechanic but he seems to be stuck... Thanks!
 
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