I have a '97 400 express.It has been setting for about 1 year very little riding during this time.Yesterday I started it to find the headlight and taillight was blown.I put a new taillight bulb in and started it when I rev the engine it blows the bulbs.I know the battery is dead will this cause it to blow the bulbs?Does anyone know of anything else that could cause them to blow or what could go out from setting.[img]i/expressions/face-icon-small-confused.gif[/img]

 

Yes the battery being dead could cause this.You can pick up a replacement battery at Lowes for cheap.

 

Dead battery is doing it.

 

Ok great I will get a new one this weekend.I hope that is all it is.It had me worried it might be something more expensive.I didnt know the battery would cause it.Does anyone know if there is someplace you can get replacement headlight bulbs for the 97 express 400 rather than the polaris dealership.Im sure they are expensive there.And will it hurt to ride it with the battery dead.It starts ok with the crank rope.The brushes have been out in the starter for a while.Thanks for the help to everyone.This is cool there is a place like this for people to go and people out there willing to help.Ride safe and have fun!!![img]i/expressions/face-icon-small-smile.gif[/img]

 

At the risk of oversimplifing things you can look at the battery like a big "filter" or "buffer" in your electrical system- cleaning and evening out the voltage that is coming from your alternator/generator...my guess is that with the battery dead you are stressing every electrical component on your quad. The lights blowing out are certainly a bad sign that things are not working the way they should. Get that battery replaced!

 

How hard is it to put brushes in the starter on a 97 Xpress 400? Do you need to have any kind of special tools?

 

Rebuilding the starter is a piece of cake. You can get rebuild kits on Ebay for $35. Getting to the starter can be the difficult part.

 

Your battery has an internal open circuit so it's like running the quad without the battery cables connected. The system voltage will be almost double normal at higher engine rpms, the voltage regulator will not function due to the battery problem. I wouldn't run it like that, the cdi may get damaged. Get a new battery and some firm foam that will isolate the battery from vibration and extend it's life.

 

If you have the headlight pod on the handlebars, that is a standard Halogen headlight bulb, like for a car. Take it in, and match it up at a parts store.

Taillight is a standard bulb, as well.

 

Thanks farmer123 and Powerslider.Now that I understand a little more how the system works it make alot more sense how it could blow the bulbs.This site is cool!![img]i/expressions/face-icon-small-happy.gif[/img]