I have a 99 Xplorer 400 4x4 and just recently the pod headlight stopped working. I thought it was a bad bulb, since it is 7 years old. Anyway, I replaced the bulb and it still doesnt work. I checked the voltage at the plug and it was good, around 14v, then I took apart the headlight switch assembly and cleaned , regreased and reassembled it. Still nothing, the voltage drops to zero when the bulb is plugged in. Does anyone have any ideas on this.

Also, where can I find a detailed electrical schematic or diagram?

Thanks

DD

 

Check ebay for a parts manual, they have schematics. If it's dropping to zero when the bulb is in, sounds like another bad buld. Should be completing the circuit and not leaving it open.

 

digger,

try the new bulb across a battery. It should light up. Sounds like you have juice going to the bulb, so all you need is a good ground.

 

After both bulbs tested fine, I followed all the wiring back, cleaning all the connections and re-greasing them afterwards. I cleaned , greased and checked all battery connections. I also tried connecting the positive wire from the pod to the bulb, and connecting a new ground wire right to the frame, from the bulb. I was about to give up for the night, but as I was testing the wiring with my multimeter, I tried bypassing the last connector to the pod, voltage was good, and to my surprise there was enough current to light the bulb. So I reassembled everything and it is working now. I guess it was a bad connection on the positive lead, not exactly sure which one, but they all had some corrosion on them and needed cleaning anyway.

Thanks for the advice!

DD