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No head lights, tail lights or hand warmers

RMKillR

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Wisco
Anyone had this issue. Started the sled this morning everything was working, let it warm up went to leave and no head lights, tail lights, brake light or hand warmers.

Thanks



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RMKillR

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Wisco
Replaced all the relays, was running Panasonic relays already. All the plugs and connectors have been greased since day 1. Tried swapping the two pack of capacitors under the console, swapped voltage regulators. Still nothing. Have been wiggling connectors and nothing still


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Csellors

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May 8, 2012
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headlight and handwarmers not working

Just had this happen on my 17. Right below the airbox there is another bag with connectors in it. The one that comes from the stator is probably melted. We cut the connector out on mine and soldered/ shrink wrapped it back together.
 

Madtown

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Nov 8, 2008
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Friend just had this issue. His was a combination of mouse that chewed some wires & bad capacitors under the console. Check fuses as well. He ohmed out the capacitors & found two of the five bad. P/N is 4013412
 

RMKillR

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Where are the fuses located? My white stator plug is not melted


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RMKillR

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Bringing it back,

Went through the sled last spring, stator connector was not melted, checked connections and such and put the hold back on and everything worked.

Well yesterday end of the day the head lights flickered a few times and lost head lights tail light, hand warmers again. Gauge cluster works. Looked again at the white stator plug, not melted, doesn’t look like any corrosion (applied dielectric grease to all the connectors when the sled was new) I swapped capacitors last year with another sled. Have looked for ohm steps, anyone have any info or link?


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RMKillR

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Well just found the stator harness rubbed on the coolant pipe, cleaned them up and found 1 orange wire with copper showing. moved the wires away and still no lights. Could that have Burnt up the stator?


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T
Nov 16, 2010
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I had the same thing last winter ended up being my stator connector. I put on a new stator cuz I thought mine was bad but the new one works the exact same so if you need a stator I have one ill sell ya only had 500 miles on it and works the same as a new one.
 

RMKillR

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Well found the problem, it was the white stator connector looked at it closer and what I thought was di electric grease smeared around was actually melted plastic, and the tin connectors in side had moved around. Temporarily splice them together to test the sled and back to normal


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RMKillR

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Wisco
When you get to the permanent repair, any pictures would be greatly appreciated.

Bought a weather pack kit, with pinning and crimping tools, and a 4 wire plug. I’ll post pictures


I looked at that plug last year and it looked fine, and even recently, thought it was dielectric greased smeared around but after touching it it was melted plastic.. and then I noticed the connectors moved back in the plug as well


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S

Spaarky

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maybe its just the ecu plugs... but I remember some posts about dielectric grease does not working well on the Axys connections. I don't remember the exact comments. Sorry, getting old.
 

RMKillR

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maybe its just the ecu plugs... but I remember some posts about dielectric grease does not working well on the Axys connections. I don't remember the exact comments. Sorry, getting old.

Yea that was posted in the relays thread


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RMKillR

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Installed the new connector tonight. Stator side is 16ga, voltage regulator side is 14ga

I previously cut the sh*t connector out and “loosely” crimp spliced them together to see if the lights worked. I labeled each side with colored tape

27c0f57d84f1c2c8edb735e7b6a29aac.jpg


Removed my temporary splice connectors

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Weather pack seals on the wires.

1e271235a09a5dfe7c5baa92d4e2f5bf.jpg


Weather pack terminals crimped on

eb4f6c19ecbe35f8014b11fa7ddbe946.jpg


4 terminal plug I’m using

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Terminals pushed into each plug end and snapped together

263db0773031b9a79b85b02f38325f13.jpg


Pictures of each side of the plugs

ca41e60fb0dd9918b3addb06af9f0da0.jpg


3d4f4e031f57ebbe1050c3aad2b566ea.jpg


Plugs connected

16c80ce573a8697279766cc5aafc7270.jpg



And my headlights, tail light and hand warmers are back!!

9dff4b700440f7e4ec42ed24c3f9c86c.jpg



I used this weather pack connector kit and tool

33a68e9e43b7f193336d9e5f38b39434.jpg


Won’t let me post a link

Hope it helps!
 
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