REVOLT Regulator & SurePower ECM Bypass Harness for Polaris Sportsman & Magnum 2003-2006
REVOLT Regulator & SurePower ECM Bypass Harness for Polaris Sportsman & Magnum 2003-2006
SKU:RMS020-107998
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REVOLT Regulator & SurePower ECM Bypass Harness Kit
Polaris Sportsman, Magnum & Trail Boss 330-700 - 2003-2006
Many years of Polaris ATVs used the SurePower ECM module, which controlled a great deal on the vehicle - circuit breakers, cooling fan operation and, most importantly, voltage regulation for the battery charging system. Most of those functions are reliable. The voltage regulator is the exception: it often fails, and that normally leaves you replacing the entire module for the sake of one function which is likely to fail again.
This RMSTATOR kit removes that problem for good by pairing the SurePower module regulator bypass harness with a REVOLT voltage regulator rectifier. REVOLT was developed over two years of research and development to fix the weak rectifier design behind roughly 85 per cent of powersports voltage regulator failures. Its Arctic Frostbite housing is CNC machined from high quality billet aluminium with deeper fins, so it dissipates heat considerably faster and runs far cooler than a standard unit. Mount the regulator on the frame, plug in and route the harness to the stator connector and the battery terminals, and the machine is ready to ride. The kit is intended to bypass the internal voltage regulator on Polaris ATVs using the older black box and the newer silver box SurePower ECM module with a single large connector. Part number RMS020-107998.
Key Features
- Bypasses the failure-prone voltage regulator inside the Polaris SurePower ECM module
- REVOLT redesigned rectifier technology, addressing the cause of about 85 per cent of regulator failures
- Arctic Frostbite CNC machined billet aluminium housing with deeper fins for faster heat transfer
- Plug and play bypass harness with 1000 mm wires and mounting hardware included
- Rated to a maximum charging current of 50 A / 500 W
- Engineered, designed and manufactured in North America
- Suits both the older black box and the newer silver box SurePower module with a single large connector
Technical Specs
| Specification | Detail |
|---|---|
| Regulator width | 103 mm |
| Regulator length | 102 mm |
| Regulator height | 26 mm |
| Fixation holes, centre to centre | 78 mm |
| Number of plugs (regulator) | 2 |
| Number of pins (regulator) | 5 |
| Number of wires (regulator) | 0 |
| Minimum charging voltage | 14.5 V +/- 0.5 V |
| Maximum charging current | 50 A / 500 W |
| Open circuit voltage | Less than 15 V |
| Operating temperature | -20 C to 85 C |
| Harness wire length | 1000 mm |
| Harness yellow wires | 3 |
| Harness red wires | 1 |
| Harness black wires | 1 |
| Harness plugs | 3 |
Vehicle Fitment Guide
Years shown are the overall coverage span for this part. Please confirm against the OEM part number on your original unit before ordering.
| Make & Model | Years |
|---|---|
| Polaris Sportsman 330-700 | 2003-2006 |
| Polaris Magnum 330-700 | 2003-2006 |
| Polaris Trail Boss 330-700 | 2003-2006 |
OEM Part Number Cross Reference
Aftermarket replacement. OEM part numbers are listed for reference only.
| Part Number | Manufacturer / Brand |
|---|---|
| 4010684 | Polaris |
| 4011088 | Polaris |
| 4010937 | Polaris |
| 4011110 | Polaris |
| 2203348 | Polaris |
| 2203349 | Polaris |
| 4010697 | Polaris |
| 4010944 | Polaris |
| 4011085 | Polaris |
| 2203130 | Polaris |
Frequently Asked Questions
Does the kit fit without modifying the machine?
Yes. The bypass harness is plug and play. The regulator mounts to the frame with the supplied hardware and the harness routes directly to the stator connector and the battery terminals. Allow for a regulator body of 103 mm by 102 mm with fixation holes 78 mm apart, centre to centre.
What is included?
A REVOLT heavy duty CNC aluminium MOSFET voltage regulator rectifier, a plug and play wiring harness with 1000 mm wires, and mounting hardware.
How do I know the regulator inside my SurePower module has failed?
Typical symptoms are a battery that will not hold charge, charging voltage that stays below the normal 14.5 V at the battery terminals with the engine running, or a battery that overcharges and boils. If the rest of the SurePower module still functions but the charging system does not, the internal regulator is the likely cause.
What makes the REVOLT regulator different from a standard replacement?
Most voltage regulator failures come from the rectifier side rather than the regulator side. REVOLT was designed specifically to improve rectifier reliability, and its Arctic Frostbite billet aluminium housing dissipates heat considerably faster, so the unit runs much cooler in service. RMSTATOR back it with a limited lifetime warranty.
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