Polaris voltage regulator bullet connectors

[D60]

I've been having to mess with the VR on an old '02 Ranger. Most will know these die and allow overcharging which slowly cooks your battery.

Later models appear to have gone to more sophisticated proprietary, multi-terminal connectors, but these old units just used bullet connectors on individual wires. I kinda appreciate the simplicity.

This caused me to research how bullet connectors are sized because the Polaris pieces seemed slightly larger than the over-priced packs you'd get on the shelf at Autozone.

Apparently they're sized in increments of 0.5 mm and the cheap ones I have from auto parts stores are 4mm. In this application Polaris used 4.5mm and I wanted to have some on hand.

I finally settled on getting some from Belmetric. They list them as .180" which is of course 4.5mm

Seen here with the old VR in background

I'm only posting because this might help someone in the future. It's not unusual to see these old Rangers still for sale in my local classifieds, so they're still out there

 

[D60]

Also for us old school Amuhreecans 4mm is pretty much exactly 5/32" but 4.5mm is extremely close to 3/16"

You can force the two to play together but it's not elegant.

I wanted to stay with the factory 4.5mm setup because I anticipate just swapping cheap Chinese regulators every year or even every few months. New units come with the 4.5mm bullet connectors already but I wanted to be able to do "factory repairs" to stay as plug 'n play as reasonably possible.

 

[BrianF]

I ran into this problem as well. The VR on my 2000 Polaris Magnum had some issues. Well rather the connectors did. I didn't realize they came in those increments so I had to crimp down the female end to mate up with new ends.

 

[D60]

I ran into this problem as well. The VR on my 2000 Polaris Magnum had some issues. Well rather the connectors did. I didn't realize they came in those increments so I had to crimp down the female end to mate up with new ends.

On this Ranger a flakey connection here caused a no-start. The electric fuel pump won't run if one of the yellow wires isn't connected properly. This one is carbureted but has a factory electric fuel pump