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post #1 of 7 (permalink) Old 11-09-2011, 02:07 AM Thread Starter
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Electrical/wiring difficulties

I have a 1997 Polaris ultra SPX, in showroom condition. Every once and a while when i'm riding on the river the headlights, dash lights, and all the warmers go off. They come on intermittently as i continue to ride but at night it just isn't reliable. I've checked some of the grounds and the cannon plugs that i can see with the air box off but nothing seems to fix it. Is there anything that i should be specifically looking for, or a place where multiple grounds meet under the block or any suggestions?
Also, does anyone have a link to a wiring diagram that i could take a look at?

Thanks
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post #2 of 7 (permalink) Old 11-09-2011, 03:30 AM
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post #3 of 7 (permalink) Old 02-07-2012, 01:28 PM
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Originally Posted by Reuas View Post
I have a 1997 Polaris ultra SPX, in showroom condition. Every once and a while when i'm riding on the river the headlights, dash lights, and all the warmers go off. They come on intermittently as i continue to ride but at night it just isn't reliable. I've checked some of the grounds and the cannon plugs that i can see with the air box off but nothing seems to fix it. Is there anything that i should be specifically looking for, or a place where multiple grounds meet under the block or any suggestions?
Also, does anyone have a link to a wiring diagram that i could take a look at?

Thanks
I have the same issue on my 94 XLT and posted it differently in here and everyone suggested a ground/short. I also went through all the wires/connectors/ground points I could see but didnt really address anything. I rode about 90 miles this past weekend and it was dusk when we got back to camp with VERY dim lights. One of the guys I rode with noticed, pushed on the resistor and it glowed and the lights got bright. After seeing that, I think maybe it is faulty? I found one on ebay for under $20 with shipping so am going to throw that in when it arrives later this week. Let me know if you found out something different please.
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post #4 of 7 (permalink) Old 02-07-2012, 02:33 PM
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Originally Posted by wheadman66 View Post
I have the same issue on my 94 XLT and posted it differently in here and everyone suggested a ground/short. I also went through all the wires/connectors/ground points I could see but didnt really address anything. I rode about 90 miles this past weekend and it was dusk when we got back to camp with VERY dim lights. One of the guys I rode with noticed, pushed on the resistor and it glowed and the lights got bright. After seeing that, I think maybe it is faulty? I found one on ebay for under $20 with shipping so am going to throw that in when it arrives later this week. Let me know if you found out something different please.
I've also had the same problem and I tried one of those cheap voltage regulators and still had the same problem. After trying the new cheap voltage regulator, I went through my entire electrical system again and could not find a problem. I finally bought one from a Polaris dealer and it has been working perfectly. (you get what you pay for)
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post #5 of 7 (permalink) Old 02-07-2012, 04:25 PM
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(you get what you pay for)
I hear ya there. This is supposedly a genuine polaris part that is used. Ill throw this one in and see what happens.
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post #6 of 7 (permalink) Old 02-07-2012, 04:44 PM
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That problem is more than likely a bad ground to the voltage regulator. My son's xcr440 did exactly the same thing, as the 96 xcr 600 i just bought did. Both were fixed by sanding the aluminum tab shiny clean, and making sure the grounding terminals were clean and shiny, to be extra sure, I used shiny new bolts to fasten it to the frame, making sure to wire brush the mounting point to clean up any rust. Both now have bright, steady lights, so I would make sure the regulator is grounded good. The orange light on top should be visible when it is running correctly.

2000 Indy 500 XC, Fox shocks up front, M10 trail in back. '99 440 XCR for my son. 96 XCR 600 SP tripple pipe, 862 miles on it !! (until it snows....then look out, odometer !!)
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post #7 of 7 (permalink) Old 02-07-2012, 04:51 PM
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That problem is more than likely a bad ground to the voltage regulator. My son's xcr440 did exactly the same thing, as the 96 xcr 600 i just bought did. Both were fixed by sanding the aluminum tab shiny clean, and making sure the grounding terminals were clean and shiny, to be extra sure, I used shiny new bolts to fasten it to the frame, making sure to wire brush the mounting point to clean up any rust. Both now have bright, steady lights, so I would make sure the regulator is grounded good.
Ok, that is good to hear. I will try to clean the contacts and see if that fixes the issue.

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The orange light on top should be visible when it is running correctly.
So that orange 'glow' is supposed to be there? It was quite bright but I will take your word for it.

Thanks for your help.
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