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First off i am new to this forum. I am having a problem with a 1995 KLF 300 Bayou atv. I have replaced the rectifier once already, it had burned up a battery. This fixed the problem for a good while. Now the replacement is getting extremely hot, smoke comes from it and it smells of burnt electronics. Also the engine has a dead miss at high revs like the ignition is retarding. It idles, starts, and runs flawlessly otherwise. It has done this for quite a while, it started doing this shortly before the first rectifier replacement. My question is are these problems related and what is the fix?

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I would say the problem is related, and would start out by looking for a bad ground if the battery is within specs for charge. If the grounds are good, then check your stator for a short. Check the lights, and make sure you do not have a light filament shorting, causing too high a load.

The new rectifier is likely now failing if it was hot enough to smoke.

These type of problems can also be from a failed or failing battery allowing the system voltage to rise too high.
 
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