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99XC 500 electrical(lights) issue
started by trailjunkie
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October 11th 2009 at 10:19 AM
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trailjunkie
New Member
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53 Posts 
Group: Members
Member Since: February 3rd 2007
Current Sled: '99 Polaris XC 600
2008-2009 Miles: 600
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My kids 99 xc 500 has a lights problem. They flicker, go dim, and go out. Then they will come back on. It had a plug for a heated sheild that was not really wired in well, just kinda tucked into the plug on the voltage regulator, removed that. the connector on one side of the VR had a blister on it keeping it from seating all the way, fixed that and gave it a squeeze, so thats tite. The main harness plug under the oil bottle is rather oily and damp in side. I have wiggled wires everywhere from under the handlebar pad all the way up to the head lights. When the lights go out, it is all of them, dash, tail, headlight, even that glowing light on the VR. Tach even seems to drop to nothing. I am stumped. Any ideas guys of what else to look for? Sled runs just fine when the lights are out. Havnt pulled the seat to look at the wires runnin under there yet.
'99 XC 600
1.25" track
SS rumble pack
Rox 3.5" risers
coming soon- boost bottle
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Site Supporter
Group: Site Supporters
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October 11th 2009 at 11:18 AM
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dtmmil
Senior Member
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3182 Posts 
Group: Members
Member Since: January 27th 2007
Location: Hawley, MN, USA
Current Sled: 99 xc700
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Possible bad voltage regulator.
Clutched
Jetted, boyesen reed petals, boost bottle, 98xc carbs slides, 1371 needles, gutted air box
Homeade 7 1/2" riser
Homeade suspension drop brackets
shortened and blackened windshield
powermadd handguards
144 conversion, tracks usa extensions, custom tunnel extension and rear bumper, IQ flap, 1.25" track
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October 11th 2009 at 11:55 AM
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mudge_77
Starting Member
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14 Posts
Group: Members
Member Since: October 9th 2009
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I had the same problem on my 98 xc 700 especially when it was cold. The lights would come on but very dim. Once in a while they would flicker and then go real dim and then bright. I chased all the wires and still did the same thing so I took the voltage regulator off and cleaned the backside of the regulator and where it attaches to the sled as well as cleaned up all the connectors and that seem to solve the problem for the last 3 months that I owned it
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October 11th 2009 at 12:06 PM
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sledneck1978
HAIL CHASER
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2143 Posts
Group: Members
Member Since: August 9th 2007
Location: Andover, MN
2008-2009 Miles: 875
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Hardwire it from the light to the regulator and if it works fine then you know it's somewhere in between. Then if it is somewhere in the middle just start at one end and work your way to the other.
"You miss 100% of the shots you don't take" (Wayne Gretzky)
"Not everyone gets off to a great start, but you have to start to be great" (Zig Zigler)
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October 11th 2009 at 12:52 PM
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trailjunkie
New Member
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53 Posts
Group: Members
Member Since: February 3rd 2007
Current Sled: '99 Polaris XC 600
2008-2009 Miles: 600
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Mudge_77,
Does the VR ground through the chassis on the backside where it is bolted on?
'99 XC 600
1.25" track
SS rumble pack
Rox 3.5" risers
coming soon- boost bottle
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October 11th 2009 at 2:55 PM
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Gee3
New Member
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82 Posts
Group: Members
Member Since: December 24th 2008
Location: Alberta, Canada
Current Sled: 93 650 RXL SKS
2008-2009 Miles: way more
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Quote originally posted by trailjunkie
Mudge_77,
Does the VR ground through the chassis on the backside where it is bolted on?
Yes, it does.
Everybody needs a good wedgie.
93 RXL SKS (All stock and proud of it)
98 RMK 600 (Son's)
93 500 EFI (My trail sled)
95 Touring SLE (Momma's Cadillac Pimpmobile)
79 Jag 3000 FA (Daughter's, nice little sled)
76 TNT 340E (Goes like hell)
78 Everest 440E (Just keeps going and going...)
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October 11th 2009 at 5:39 PM
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mudge_77
Starting Member
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14 Posts
Group: Members
Member Since: October 9th 2009
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Quote originally posted by trailjunkie
Mudge_77,
Does the VR ground through the chassis on the backside where it is bolted on?
Yes. I used a little wire brush and cleaned it up really good and also cleaned up the connector as well
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October 11th 2009 at 7:12 PM
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SNOWRIDA_07
Starting Member
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1 Posts
Group: Members
Member Since: October 11th 2009
Location: Mayville, Wisconsin, USA
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i experienced the same problem on my 99 xcsp 600. Headlights would go off and on while riding. Be sure to check all of your bulbs on your sled, when my VR took a sh*t it blew out all three of my headlights. Changed the VR and all bulbs, no further problems.
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October 13th 2009 at 7:35 PM
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aurex
Starting Member
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6 Posts
Group: Members
Member Since: May 18th 2009
Current Sled: 2000 Polaris XC500SP
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Quote originally posted by trailjunkie
My kids 99 xc 500 has a lights problem. They flicker, go dim, and go out. Then they will come back on. It had a plug for a heated sheild that was not really wired in well, just kinda tucked into the plug on the voltage regulator, removed that. the connector on one side of the VR had a blister on it keeping it from seating all the way, fixed that and gave it a squeeze, so thats tite. The main harness plug under the oil bottle is rather oily and damp in side. I have wiggled wires everywhere from under the handlebar pad all the way up to the head lights. When the lights go out, it is all of them, dash, tail, headlight, even that glowing light on the VR. Tach even seems to drop to nothing. I am stumped. Any ideas guys of what else to look for? Sled runs just fine when the lights are out. Havnt pulled the seat to look at the wires runnin under there yet.
I had the same problem last year with my 200o xc500sp. Check the wire harness on the left hand side (looking from the rear of the sled) near the front of the hood. there should be a bracket there that holds the wiring and a hood support. From vibration, the wires had worn through and would go out when the exposed wires touched the hood support.
Cheers.
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October 13th 2009 at 9:13 PM
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scaryfast
Junior Member
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288 Posts 
Group: Members
Member Since: September 20th 2006
Location: Rockford, Michigan, USA
Current Sled: 2000 Polaris SKS 700
2008-2009 Miles: 600
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AUREX said it,
My 2000 SKS did the same thing, my low beams wouldnt even work, turns out one of the wires was worn through and was rubbing metal.
days get shorter, nights get longer, snow gets deeper, life gets better
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October 13th 2009 at 9:44 PM
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whitexc
Average Member
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948 Posts 
Group: Members
Member Since: February 19th 2006
Location: Pendleton, NY, USA
Current Sled: XC
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Voltage regulator....
Polaris...it IS the way out!
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