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Old 02-02-2008, 09:19 AM   #1 (permalink)
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faulty hand warmers

New here to the forums, I was hoping to cash in on the wealth of knowledge here. The problem I am having is with the hand warmers on our 1994 440 Cougar, neither work. I was wondering what is the most common problem with them? Ground? Power? Switch? warming units themselves? The switch is just an on/off, not hi and lo. Any help as to where to look first would be appreciated.
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Old 02-02-2008, 03:48 PM   #2 (permalink)
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How many volts should be at the switch for the hand warmers with the machine running?
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Old 02-02-2008, 09:22 PM   #3 (permalink)
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12VDC. Measure the switch voltage (input to ground, then the output to ground).
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Old 02-02-2008, 10:23 PM   #4 (permalink)
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Not sure I understand, the switch has two leads a double brown and a green. Are you saying to measure the green?
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Old 02-03-2008, 11:07 AM   #5 (permalink)
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With the engine running one of the leads on the switch should have 12volts the other one nothing with the switch off, then with the switch on both terminals should have power. I believe the power runs through a ceramic resister, that is where the problem is a lot of times, a bad resister.
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Old 02-04-2008, 03:21 PM   #6 (permalink)
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Ok an update, I checked the voltage at the switch. No where near 12 volts, I have another machine a 1994 EXT which is very similar only the hand warmers work, checked the voltage on this one and it doesn't show 12 volts either? Not sure what I am doing wrong. Also I am assuming that the hand warmers would run off the power from the lighting coil? All the lights on both sleds work fine. Could there be something wrong with the lighting coil if the lights are working?
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Old 02-05-2008, 03:46 AM   #7 (permalink)
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Check continuity through the elements, you might have a broken wire or burned out element.
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Old 02-05-2008, 08:55 AM   #8 (permalink)
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You probably won't get a full 12v until the rpm's are up to about 3500. The main thing is if you have power at all going to the hand warmers. If you do and they still don't work I think you have to ohm test the heating elements them selfs on the hand warmers. Are the lights working good? Nice and bright? Not going bright then dim with rpm?
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Old 02-09-2008, 03:18 PM   #9 (permalink)
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The voltage to the green wire is less than 1 volt with engine running, if the lights are working ok could it be the lighting coil? Our other sled which is similar has around the same voltage at the green wire, but the warmers work. Tested the lighting coil as described in my Clymer manual, ohms should be around .11 +/-10% I get a .20 reading. Any one have anymore ideas? Ground? And if so is there a main ground and where would it be located?
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Old 02-09-2008, 04:40 PM   #10 (permalink)
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You must be getting 12 volts to your headlight or it would be really dim. The hand warmers should get power from the lighting coil that should be 12 volts for running the lights and any accessories. The actual power to the headlights should be regulated so the power goes from the lighting coil through some type of regulator then to the lights so you don't blow bulbs. But a lot of sleds run power from the lighting coil unregulated to the hand warmers, but run regulated power to the thumb warmer so it doesn't melt the plastic throttle lever. that is if you have a separate switch for hand warmer and thumb warmer. And if you have a high and low switch for the hand warmer the low side goes through a resister to decrease the voltage. There was that confusing enough.
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Last edited by eriksat1; 02-09-2008 at 05:39 PM.
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Old 02-09-2008, 05:57 PM   #11 (permalink)
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Sounds like your problem is only 1 volt to the switch. Run 1 volt to your headlight and see how bright it is. You need 12 volts to your hand warmers or they won't heat up. Trace back the wires to find out why you aren't getting 12 volts, I'm assuming your headlight is working ok.
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Old 02-09-2008, 06:36 PM   #12 (permalink)
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Thanks eriksat1 will try to trace back, easier said than done as I am sure you are aware. Yeah headlight seems to work fine, I wasn't sure if it were possible for the lighting coil to short out but still provide enough power for the headlight.
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