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Polaris: GEN 2 1999-2001, all models in the Gen 2 chassis
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Old 12-26-2017, 09:24 AM
ToronadoGT455 ToronadoGT455 is offline
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Default 99 RMK lights keep blowing

I have a 99 RMK that the lights keep blowing out, I have replaced the regulator with a after market part, It take less that a few minutes for them to go out, also the high beam indicator glows dim until I bring my RPM's up, also the tach doesn't work. I have taken the seat off to eliminate the rear wiring.
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Old 12-26-2017, 02:27 PM
retiredpop retiredpop is online now
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Get hold of a voltmeter so you can read the voltage from a yellow wire to ground. It should be no more than 15 VAC with the regulator connected and motor revved up to 3000 rpm or so. The tach runs off the lighting voltage. Usually it doesn't blow when the regulator goes bad.
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Old 12-26-2017, 05:06 PM
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Also make sure the ground where the regulator is bolted to is clean and corrosion free as it is the ground reference point for the regulator. I usually put a star washer on it so it gets a good bite onto the regulator.
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Old 12-30-2017, 01:44 PM
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Ok, so I put on the new updated style regulator and made sure it was grounded,checked the voltage. Still over charge,I even tried a led bulb rated at 12-24v and it still flicked and burned out, the tach is working intermittent,volts are 8 idling but are as high as 30 at higher rpm,did I get another bad regulator?
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Old 12-30-2017, 05:14 PM
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It sure sounds like it or else there are some wiring issues. You should never see more than 15 VAC at higher rpm. Make sure the harness side of the connector for the regulator is good. Check right at the connector for the AC voltage. I have had new regulators go bad after a short period but not usually right away.
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Old 01-01-2018, 09:39 AM
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Ok, I did some more checking, I had my volt meter on AC not DC so on DC I get no voltage at the headlight or at the regulator but I am still getting lights for a little while from somewhere, Iím guessing my lighting coil is bad, so itís built into the stator but is separate from the ignition system part but must be replaced as one unit? Is there a way to test it?
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Old 01-01-2018, 11:01 AM
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The headlights are AC...as are the Handwarmers.




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Old 01-01-2018, 11:03 AM
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The lighting circuit is AC not DC. Your meter needs to be set to VAC to test the voltage of that circuit. Like retiredpop mentioned, you should have no more that 15 VAC otherwise you'll continue to burn out the lights.

Someone with a schematic will hopefully post resistance values for the lighting coil. It won't hurt to check this but given the problem you're having, which appears to be overcharging, I doubt you'll find anything wrong.

It seems you have either gotten a dud new voltage regulator or the regulator itself is not properly grounded. I'm not sure how that machine is wired but there could be a ground fault between the stator & the chassis yet the ground to the lighting circuit is still intact.

That's where the schematic would come in handy.....

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Originally Posted by ToronadoGT455 View Post
Ok, I did some more checking, I had my volt meter on AC not DC so on DC I get no voltage at the headlight or at the regulator but I am still getting lights for a little while from somewhere, Iím guessing my lighting coil is bad, so itís built into the stator but is separate from the ignition system part but must be replaced as one unit? Is there a way to test it?
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Old 01-01-2018, 11:28 AM
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Try using a regulator from a 900 Arctic Cat, they seemed to be much heavier duty.
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Old 01-01-2018, 12:00 PM
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Old 01-01-2018, 04:13 PM
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Old 01-01-2018, 07:51 PM
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