Polaris burning out headlight bulbs...

[dustin85]

I have a 94 Storm 800. At the end of last winter, my headlamp burned out. I replaced it with a used one that I had in the garage. Today, my 1st time out for the year, it burned out as I left the driveway. I bought a new bulb, installed it....and same results. I have had this sled for about 3 years, and I have not changed anything electrically on it. I did not touch the glass as I was putting it in. Is this just bad luck, or do any of you know of something else that I should be looking into? I am kind of bummed that it happend now...when we are supposed to have the best snow we have had for a long time.

Dustin

[Macgyver55]

Sounds like a voltage regulator problem. But voltage spikes can also be caused by loose connections or poor grounds that arc from vibration. Trace all the wiring and connectors to look for frayed (mice chewed) wires or loose plug connectors or grounds. If all looks good, replacing the regulator will probably need to happen.

[Eelpout08]

Check to see how many volts you have at the bulb. take the plug off the bulb and hook a meter to it while the sled is running. it sounds like your voltage regulator isnt working.

[dustin85]

I will put a meter on it tomorrow to see what voltage I am getting at the bulb. From my initial inspection, th wires and connections looked o.k. Where is this voltage regulator located?

[jeffreyd]

also check the battery connections to make sure one is not loose

[dustin85]

At idle I am getting about 10VAC at the bulb socket. When it is revved up a little it reads 22V+. I guess I expected to see DC Voltage. When I tried to measure DC it was flatlined 0. Should I just expect to see right around 12V at the socket? Thanks for the help!

[Macgyver55]

If its putting out 22+ volts and all of the wiring and connections look good I'd pick up a regulator. The bulbs are 12 volt and will be ok up to about 15 max volts, then they become "flashbulbs" after that. Unless you have electric start and a battery, the lights on your sled work off a lighting coil which produces AC voltage, so it wont register on a DC gauge.

[furnace man]

It is the voltage reg for sure.

[dustin85]

That makes perfect sense to me now! Thanks for the help!

[dustin85]

I picked up a new voltage regulator, and it is all back to normal. Thanks again for heading me in the right direction!

Dustin