1999 Polaris XC500 Issue

[MNUser]

The sled seems to have a short. Not sure if it is a common problem o not so I thought i would try here before I seek "professional" help.. ; )

The headlight and tail light will dim out and then come back to full strength. The hand warmers and thumb warmers work fine. I have checked some of the connections and found nothing that seemed loose. Was wondering it is was under the seat.

Anybody have this issue with this sled? If so, what was the fix?

Thanks!

[Macgyver55]

You could rule out the tail light circuit by unplugging it before it goes under the seat then running it and seeing if the headlight still dims. Otherwise I'd say the voltage regulator is possibly going bad.

[Scott Stein]

our 99 Supersport did that last yr and now headlight/tailight/hand warmers dont work! takin it in soon to have to checkd out,ill let ya no what i find out

[Paul Waldowski]

Mn,

I would bet that it's the voltage regulator. Had the same problem and tried to find the short all in vain. Even had it in and they thought they found the short. I struggled with the problem for a month or so. Finally stopped in and talked with Eddie FM-Millelacs and he knew exactly what it was. He gave me a new voltage regulator, took me 2 minutes to put it in and haven't had one problem with the lights since.

[Scott Stein]

paul do you remember how much that regulator cost ya??

[Paul Waldowski]

I think it was like $25 or so. It was over a year ago and the memory ain't what it used to be, but then again neither is the rest of me

[Scott Stein]

thats not bad...my buddy has the same sled and had the same problem and they replaced the switchs on the left handle bar and if i remember right that cost him around $300 but it fixed the problem...i like $25 over $300!!!!!!!!!

[MNUser]

Is the voltage regulator hard to find and change out?

[Paul Waldowski]

Not really once you know what it looks like. Mine was located just under the hood, just under where the recoil comes out by where my right foot would be

[MNUser]

That sounds easy. Is there a trick to determine if it is bad or not? It might be the least expensive fix to find the problem. I had considered taking it in but it could cost a fortune when you figure in their hourly rate.

Thanks!

[Shack]

Very easy. Open the hood and look on the right side (when sitting on the sled), down by the chain case. If you are standing on the right side of the sled looking at the chain case, just look a little towards the rear of the sled on the black cross bar (from tunnel to belly pan). It will be right above your right foot footrest, but in the hood area. It will be a little black box (2"x3"), with two bolts holding it on and one wire (yellow).

Good luck!

[Scott Stein]

That sounds easy. Is there a trick to determine if it is bad or not? It might be the least expensive fix to find the problem. I had considered taking it in but it could cost a fortune when you figure in their hourly rate.

Thanks!

ya the local polaris dealer around here charges $80 or $85 an hour!!! nuts!!!!!

[Shack]

It should look like this:

[Snowking]

check the main harness where the wires and the bulk head meet on the cluch side. buddy has a 2001 600 that would do the same thing turns out the wires were rubbin

[MNUser]

Thanks shackbash.

I emailed you about the voltage regulator. I will take it off your hands. I'm in Baxter, MN. Let me know what I owe you and I will get it in the mail tomorrow.

Thanks! Look forward to having this nagging little issue resolved.

[MNUser]

Thanks guys! Got the part from shackbash and installed it. All is working perfectly. Started it up and it did not dim once. Ran it for about 5 minutes or so. I think that was it. You guys saved me hundreds!

If I ever see you out and about I owe your a beer or three!