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Old 03-01-2009, 07:04 PM   #1 (permalink)
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1995 Indy 500 headlight Problems

I have 1995 polaris indy 500 and I am having a problem with the headlights.
When ever I put new bulbs in and start it up it blows the bulbs within about 5 seconds. I already replaced the voltage regulator, but the problem till occours. The sled runs great and all the other lights work (tail lights,dashlights). If anyone has any advise on what i should do next it would be great.
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Old 03-01-2009, 07:13 PM   #2 (permalink)
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Check your grounds, only 2 causes voltage regulator or ground. Pull your bulbs after next regulater and test output 1st.
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Old 03-01-2009, 07:28 PM   #3 (permalink)
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I'm good with fixing things but which grounds wires and where are they usally located???
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Old 03-02-2009, 03:30 AM   #4 (permalink)
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Not quite sure of all grounds on machine w/o schematic, however on mine the problem was in wiring to taillight under seat. Get a diagram or trace wires. Good luck, I hate elecrical and it seems I am always screwing with it,lol.
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Old 03-02-2009, 05:26 AM   #5 (permalink)
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Measure the ground prong of the headlight plug t othe sled chassis. Are you using the right OEM bulb?
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Old 03-02-2009, 08:23 AM   #6 (permalink)
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put a new voltage regulator on it and then put a new bulb in.......if you want to check your grounds.....the only "ground problem" that can blow a bulb is ONLY the ground on the voltage regulator itself.
Its the little square box behind the key control panel. it will have a yellow wire comeing out of it and then there will be a ground loop wire attached to it. The box is to route all the extra volts thats generated by the sled revving up and get rid of it by safely dumping it into the ground circut... if the box it blown or the ground loop is not connected....the voltage in the sled spikes too high blowing out bulbs,,,normally your headlight first then others.
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Old 03-02-2009, 09:14 AM   #7 (permalink)
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I agree with the problem being with your regulator, I had 2 sleds with 2 different problems, my 500xc had dim lights, and my son's 440xcr was blowing headlights left and right. I solved both problems by accident, I pulled the regulator, noticed the aluminum grounding tab was very oxidized, wire brushed it clean and shiny, also the wire connectors that went to the mounting bolt, and my 500 had bright lights again. Decided to try it with the 440, and after a good cleaning, no more blown lamps all season, so I'm assuming both problems were due to a bad ground, if a good cleaning does not solve it, just bolt in a new or used regulator, make sure all connections are as clean as possible.
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Old 03-02-2009, 03:58 PM   #8 (permalink)
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Ok I will clean the voltage regulator contacts,and I hope that it is the problem.
Thanks for the advice.
Brandon
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Old 03-04-2009, 08:20 AM   #9 (permalink)
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if you need a new regulator the cheapy ones are only 20 bucks anyhow to replace....mines lasted a while now.
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Old 03-15-2009, 07:20 PM   #10 (permalink)
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Ran tests over weekend, needs new statora and voltage regulator
I hate electrictlial problems
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Old 03-15-2009, 08:39 PM   #11 (permalink)
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j -

What is that color you used on your Polaris 500 Classic? that is a very nice color, you should get a few graphics to put on there, it would really look sharp. The only thing I noticed is the red on your seat kind of sticks out, maybe find some matching fabric for that to match the hood?
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