Need some suggestions , Friday night I was making my way home,it was after midnight and I was in the middle of the woods,2-3 miles from my home when my dash lighs started blinking and my headlights also. this lasted for 5mins and then 1 by 1 headlights blew. The dash lights continued to go in and out and I also lost my four wheel drive. Needless to say it wasn't fun getting out of those woods and through the mud holes with a disposible flash light. I checked the bike over Saturday morning,found the electric start wouldn't work. I had the headlamp mod installed so the first thing I done was check it ,couldn't find a problem or short ,unhooked it anyway. Checked my battery voltage and it was down to 9.4 volts recharged the battery. installed the battery bike then would start off electric start. fourwheel drive is working also. everything is working headlights are getting power. The bulbs are all blown so I need to pick them up today. Checked the voltage with the bike running and it was charging at 14.8 volts. This is the same voltage being delivered to the headlights also while bike is running. The tail light / brake light worked through this whole episode also. Could I have had a short on my headlight mod? do I need to double check my voltage regulator? what's a good replacement bulb for my head lamp ? help please

 

First thing I would do is check ALL of your grounds. Look close at how the VR is grounded.

 

I went bumper to bumper yesterday, checked and cleaned all connections. I'm sure the short came from the Headlight Mod. If it was the voltage regulator it would have blown my tail light . I'm trying to locate after market bulbs dealer wants almost a $100

 

I would use a volt meter to see what your voltage is really doing while idleing and while turning a few thousand RPMs to be sure.

 

It was 12.4 with the engine off, and with it turning a couple thousand it was 14.6 . I'm trying to find a replacement bulbs. The polaris dealer wants $30 per for the low beam $70.00 for low beam bulbs I think is a bit much

 

Check your battery. I read in a post a while back that it helps to regulate the power to the lights.
[img]i/expressions/face-icon-small-sad.gif[/img]

 

My battery was way under charged when this happened ?

 

Sorry KINGSCLEAR, I misread your post. I though you blew all the lights in your quad, not just the headlights.
Other than a bad VR I just don't know what would cause this. Even with a voltage spike from the low battery, the VR should have taken care of it. I don't see how your headlight mod can cause this, but I just don't know? Sorry [img]i/expressions/face-icon-small-sad.gif[/img]

 

Try this link for the bulbs, I got it from this forum awhile back, I think it is for the 2 lower lights, supposed to be brighter/whiter lights. Try a search for "bulbs" and look around you might find it here.
Hope this helps

Bulbs

 

Those bulbs are cool but at 50w a copy you're gonna smoke your system. The stator puts out just enough for all the systems on the factory machine. If you run 3 of those, just your headlights will consume more than 50% of the stator output. We need bigger stator on these Sportsman!