Replaced relay and still no accessories

[hotterwill]

2003 Skidoo Summit High Mark, no headlights, taillight, brakelights, handwarmers, tachometer and speedoemeter. Runs fine otherwise. I have checked the two light fuses both good, have checked wire harness all is well. Today I replaced the relay still no change, what else could it be?

 

[decarls]

By relay you mean the little black part above the primary clutch? I had the exact same symptoms on my 03 600, replaced that part... just like new.

 

[mtnpull]

I am having the same problems with some of my 08 550 rentals. The 550's don't have a relay, so I am going through the process of trouble shooting a short somewhere. We are just getting started with this, but here is our plan of attack. Just start disconnecting one electrical accessory at a time and check to see if the problem goes away. Disconnect the tail light, then the headlights, then the kill switch, then the handwarmers/reverse, then....and so on. It has got to be a short grounding out on the chassis somewhere.

You may want to see if your voltage regulator is going out or is spiking. Before starting trouble shooting for a short we first changed out the voltage regulator to ensure that was not the issue.

Let me know if you have any luck.

 

[hotterwill]

Relay

The realay I replaced is a 5 prong located on the right side of the sled just under the couling alongside the engine start pull cord next to the the two accessory fusses. Is there another one?

If not, I will go through the troubleshooting process of disconnecting plugs one at a time to see if i can located the problem.

Where is the voltage regulator located on this?

 

[decarls]

I can't say for sure since mine is a REV chassis. On my sled it was right above the primary clutch, can't remember how may prong but black & about 1'' square with a hole for a zip tie. According to the local dealer this part is pretty a common failure after about 3 years old.

 

[decarls]

I believe on the parts fische it's under "electrical system #2" part #14. I'll try to get the pic to post.

I found it on this website.

http://216.37.204.206/xtremepowersports/Skidoo_OEM/Skidoo.asp?Type=13&A=564&B=19

 

[mtnpull]

My 550's are in the rev chassis and the voltage regulator is below the motor bolted to the bulkhead on the can/chaincase side of the machine. Not sure where it will be on your sled???

 

[enis750]

hey guys

just had this EXACT same problem on my 03.5 REV Summit 800H0
i had a short in the line of the thumbwarmer

try starting the sled, with all accessoried turned off (h + t warmers)
see if it does anything
when i turned on my t warmer, boom it shut everything down
turn it back off and everything worked fine

i cut the thumbwarmer out and disconnected the wire
ran the sled last weekend w no issues...other than cold hands

i posted a pic of what the relay looks like below, as i didnt know either

 

[hotterwill]

Thanks!!

Thanks for all the input!! I trouble shot all your suggestions and still no power to the accessories. At this point I will be going through a testing process to see if the the magneito & voltage regulator are putting out volts.

 

[hotterwill]

Problem Solved!

Took the suggestion to replace the new five prong Relay that I just put in and problem solved, I now have all my lights, hand warmers, Tach and Speedometer, again thanks for all your suggestions, saved me a trip to the shop and a few hundred bucks!!!!!