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REVOLT Regulator + RMSTATOR SurePower ECM Bypass Harness for Polaris Ranger 500 700 | Sportsman 500 2005-2009 | 4011657
REVOLT Regulator + RMSTATOR SurePower ECM Bypass Harness for Polaris Ranger 500 700 | Sportsman 500 2005-2009 | 4011657
This replacement kit is only meant to the bypass the internal voltage regulator on Polaris ATV/UTVs that use the large silver SurePower ECM module with 2 large wiring connectors on opposite sides of the unit. Please confirm your OEM part number on your unit matches the list below.
Replaces these OEM Numbers :
4011089
4011090
4011598
4011375
4011657
4011226
4011517
4011240
Battery condition is extremely important. No voltage regulator can work correctly with a bad or weak battery. Always fully charge your battery before performing any charging system tests or replacing parts. If there is any doubt, have the battery load tested or replaced.

Details
Details
Many years of Polaris ATV’s used the SurePower ECM module that controlled many things on the vehicle, including circuit breakers, cooling fan operation, and most importantly voltage regulation for the battery charging system. Most of these functions are reliable, except for the most important, the voltage regulator rectifier! The voltage regulator often fails, and leaves you faced with replacing the entire module just for this one function, which is likely to fail again.
RMSTATOR now provides a SurePower module Regulator Bypass kit to eliminate this problem on these popular ATVs. Our kit includes our heavy duty REVOLT voltage regulator, a plug & play wiring harness, and mounting hardware. Simply mount the new voltage regulator on your frame, plug in and route the harness directly to the stator connector and battery terminals, and you’re ready to ride. You’ll never have to worry about a failing voltage regulator or SurePower replacement again.
Brand new REVOLT Voltage Regulator
Refuse to compromise to current 30-year-old technology. Join the revolt against bland voltage regulator performance. With its redesigned rectifier technology , REVOLT excels where every other fail: Fixing the weak rectifier design that causes 85% of voltage regulator failures in powersports applications. Welcome to a new era!
RUNS 50% COOLER THAN OEM
2 years of R&D and careful choice of top graded performance components has made REVOLT dramatically reduce failure rate by running substantially cooler than the best OEM and competitors’ products on the market
SOLVES THE MAJOR CAUSE OF FAILURE
85% of the voltage regulator rectifiers failures comes from the rectifier-side failing. While latest technologies all improved the regulator side, REVOLT is the only voltage regulator rectifier on the market to considerably improve the rectifier reliability.
DISSIPATE HEAT 45% FASTER THAN OEM
Our improved proprietary Arctic Frostbite housing has increased and deeper fins and is CNC-machined from a high-quality aluminum billet for optimal heat transfer from internal components to external fresh air.
PROUDLY MADE IN NORTH AMERICA
REVOLT is engineered, designed, and manufactured in North America under strict quality control standards. Say farewell to failures due to uneven quality control processes.
LIFETIME WARRANTY
REVOLT is so durable we are backing it with a limited lifetime warranty. Never ever will you need to change a voltage regulator.
Join REVOLT, the new era of voltage regulation!
- Direct replacement to your original unit
- Plug-and-play, direct fit, easy installation
- The quality exceeds the OEM equipment
- Improved heat sink and charging capabilities
- Higher grade of electric components
- All shipped products are tested
We have even included the opposite connector (main harness side) as we know these are often melted / corroded / defective and a major cause of repetitive electrical issues.
*All item pictures are accurate, if in doubt, do not hesitate and compare our item to your original part.
Automotive grade wiring harness with OEM-quality heavy-duty connectors
Made with the same Delphi connectors as OEM Polaris parts, our wiring harnesses are manufactured in a factory with controlled quality processes. They use the same Cross-Link braided copper wire as the OEM parts, and resist heat, oil, acid, gas and more with very low electrical resistance.
Plug & Ride design
Our voltage regulator housings are manufactured to OEM specifications for a fast and easy installation.
All item pictures are accurate, if in doubt do not hesitate and compare our item to your original part.
Specifications
Specifications
Width: 102 mm
Length: 103 mm
Height: 26 mm
Fixation holes center to center: 78 mm
Other specifications:
Number of plugs: 2
Number of pins: 5
Minimum Charging Voltage: 14.5 V +/- 0.5 V
Maximum Charging Current: 50 A / 500 W
Open Circuit Voltage: < 15 V
Operation Temperature: -20°C to 85°C
Wires Length: 1580 mm
Number of yellow wires: 3
Number of red wires: 1
Number of black wires: 1
Number of plugs: 3
Interchange Part Nº
Interchange Part Nº
-
Harness :
4011657 - 4011089
- 4011226
- 4011240
- 4011090
- 4011375
- 4011517
- 4011598
Installation
Installation
Before installing your new REVOLT Voltage Regulator Rectifier:
- Check the AC output of the stator
- Replace any burned or corroded connectors on stator and regulator rectifier
- Check and repair any melted wiring
- Use hi-temp dielectric grease on all connectors
Download our complete installation instruction (PDF)
Warning:
Risk of electric shock. Disconnect the battery before servicing.
Ensure proper installation by a qualified technician to avoid malfunction.
Vehicle Fitments
Vehicle Fitments
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