Mine 99 sportsman 500 just keeps blowing all the bulbs, high and low beam, plus taillight. I replaced the speedometer and also put a new rectifier in it. Now my high beam bulb is doing fine, but the low beams blew again, and also when riding at night, my speedometer will slowly start to fade out on lighting and also my high beam headlight will dim really low, then all of the sudden the speedo will just completely shut off then in a few minutes it will come back on bright again, this same thing just repeats over and over. I have checked battery, all grounds, replaced rectifier, ect. I cannot figure out why this is doing this. Also I notice when idling even when the break handle is applied it cuts the power down on the lighting, you can see it fluctuate in the speedo and head light. I just cant figure out what is going on. I also noticed that the four wheel drive indicator light is not coming on, when you put in in four wheel, just the left wheel pulls, I tested the wires and it seems like the right wheel is not getting power from the switch to engage.
Any Suggestions ???????

thanks,

Matt

 

Voltage regulator

 

i would have said rectifier as well but u have replaced that. sounds like your getting a dead short some where but not in a place where it runs down the batt. did u trace your break wires since you said that in goes in and out while useing the brakes. just an idear to start with.