08 Polaris Sportsman 300 Headlights Blown!

[800 Max XT]

Does anyone know why my wife’s 08 Sportsman 300 headlights blow every now and then? Here is what I know:

• Both headlights blow at the same time.
• All fuses are fine.
• Do not see any moisture in the headlight.
• All other lights are fine.

Has happened once before with the same symptoms as above, so I just replaced the headlights. Lasted about a year.

Any suggestions are appreciated.
Thanks in advance.

 

[underdog]

Sounds to me like the wire beyond the fuse is shorting out.

sent from my android

 

[OnlyPolaris]

possible voltage regulator issue.

 

[800 Max XT]

I just checked the wiring for cuts or binds. Nothing. So I put a voltage tester on the battery and it read 12.4. Started up the bike and it went to 13.6. Turned up the RPM's and the DC Volts went all the way up to 18 +. Does this sound like a voltage regulater issue? If yes why doesn't any fuses blow?

 

[Rhodesie]

fuses are there to protect the system in a dead short situation, if the charging system is cranking out 18+ volts the electrical system will carry it. Exactly what Only Poo said, regulator/rectifier is cooked. part #4011182, $138.00.

 

[800 Max XT]

Thanks for the info Rhodesie. I took the bike apart to find the regulator. Removed it and sure enough there was water behind it and there were holes melted in the back. I ordered a new one. Thanks you all for helping me figure this one out.