1994 EXT 580 efi headlight electrical issue - Snowmobile Forum: Your #1 Snowmobile Forum
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Old 12-22-2009, 08:40 PM   #1 (permalink)
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1994 EXT 580 efi headlight electrical issue

Hello all,
I could use some help.
I purchased a 1994 ext with some issues. I thought I had all the issues fixed and went to start the sled. 1st pull it fired right up. As it was running the headlight would flash and then it blew. The motor was still running fine and the rear tail light was a solid red. I also had brake lights when I applied the brake. As I was fixing some issues I did notice the connector for the headlight was deformed and melted. I replaced it with a new plug and headlight. I used my ohm meter and did some voltage checks while the machine was running. All I found was an inconsistent reading coming from the voltage. Never had a constant 12V. I shut the sled down and brought it back into the garage. I then proceeded to ohm out the wires. Each wire (3) would provide a connection to ground except for when I would toggle the bright switch, then only 2 would find a path to ground. Any ideas on what the issue is? I assume it isn't a stator since my rear tail light is constant. Do the bright switches go bad? Any help would be appreciated. I was hoping to have this sled fixed so my wife and I could take our sleds and go riding.
Thanks,
Eric
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Old 12-23-2009, 09:21 AM   #2 (permalink)
JDS
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Sounds like you need a new voltage regulator.
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Old 12-23-2009, 10:00 AM   #3 (permalink)
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Yes, the HI/LO switch can go bad.
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Old 12-23-2009, 10:45 PM   #4 (permalink)
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Well I spent some time with the sled tonight. I checked all the wires and switches. My hand warmer switch wasn't working correctly so I cleaned that switch. I also replaced a few blown light bulbs in the instrument cluster. I had another voltage regulator from another sled so I installed that as well. I have no idea if the other voltage regulator is any good but couldn't hurt to try. After doing all this I spent some time using my voltmeter to check circuits. From what I can tell the headlight is now working fine. I have one ground and I'm able to make a path to ground by using the headlight switch and switching between high and low beams. I'll start it up tomorrow and see how it goes. I'll let you all know then.
Thanks for the help.
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