Fusion 600 headlight issue

H

Hoosier

Well-known member
So on the last trip I took, the headlights were cutting in and out randomly. Not sure the cause - they would work for 10 miles, then cut out or vice versa. The sled has 4 bulbs - the inner two always stayed on but don't provide that much light. The outer two I think should always be on, whether you are on high or low. Those are the two that were cutting in and out. Starting the sled up this weekend these bulbs aren't coming on at all. We tried working through as much of the wiring as we could, checking for frays, bad connections, dirty connectors. Tried working through the wiring the best we could with a voltmeter. Couldn't find anything. The sled does have the updated voltage regulator. Any ideas? Is there a relay somewhere that I should check - I didn't see one.

I really need to upgrade...
 
T

Tracker

Guest
Hoosier said:
So on the last trip I took, the headlights were cutting in and out randomly. Not sure the cause - they would work for 10 miles, then cut out or vice versa. The sled has 4 bulbs - the inner two always stayed on but don't provide that much light. The outer two I think should always be on, whether you are on high or low. Those are the two that were cutting in and out. Starting the sled up this weekend these bulbs aren't coming on at all. We tried working through as much of the wiring as we could, checking for frays, bad connections, dirty connectors. Tried working through the wiring the best we could with a voltmeter. Couldn't find anything. The sled does have the updated voltage regulator. Any ideas? Is there a relay somewhere that I should check - I didn't see one.

I really need to upgrade...
Click to expand...

not too sure aboot polarious but a cat....the first sign....is the speedo goes out...and then the lights act up or go out....and this coincides with mileage and a cat is always at 3500 miles....so if its around that....its usually the bearings on the jack shaft or drive shaft are aboot to blow....they loosen first and when that does the magnets don't line up and start shaving themselves into oblivion and then get wedged in and break the speedo....the lights act in this same manner also.....I would raise sled up in air both front and back using the bumpers so no strain on track....no take your hand and wiggle the he!! out of the jack shaft....if it moves any....that's it...bearings shot....well hopefully thats it...good luck....my 2c
 
1

1flatlander2

Member
Hoosier said:
So on the last trip I took, the headlights were cutting in and out randomly. Not sure the cause - they would work for 10 miles, then cut out or vice versa. The sled has 4 bulbs - the inner two always stayed on but don't provide that much light. The outer two I think should always be on, whether you are on high or low. Those are the two that were cutting in and out. Starting the sled up this weekend these bulbs aren't coming on at all. We tried working through as much of the wiring as we could, checking for frays, bad connections, dirty connectors. Tried working through the wiring the best we could with a voltmeter. Couldn't find anything. The sled does have the updated voltage regulator. Any ideas? Is there a relay somewhere that I should check - I didn't see one.

I really need to upgrade...
Click to expand...

i just replaced the handle bar controller on my 07 700 the high/low (blue button)was iffy and then the lights just went out. if you wiggle the bright controller it would flash on and off
 
H

Hoosier

Well-known member
I changed the bearings out before last season, so those should be good.

I replaced the handlebar controller once before for the same reason you mentioned. I might hook up the old one again and try that, just to eliminate that as a possibility.
 
F

fcat700

Member
If I remember correctly, I believe there may have been issues with voltage regulators on the Fusion that caused that issue.
 
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H

Hoosier

Well-known member
allen_shores said:
I'm thinking voltage regulator. It already has the updated regulator, but I believe there is a newer one.
Click to expand...

I did replace it several years ago to the one you mount on the belt guard. It's possible that's bad, but everything works but the primary headlights.

Since the worthless inner headlights work, I was thinking about rewiring it to run the main 2 from those wires if I can't figure anything else out.
 
S

Snirtdawg

New member
I'd look hard at where the wire harness goes from the belly pan to the hood. My buddy bought my 06 Fusion and he had problems similar and that got rubbed or kinked in that area.
 
F

formula_iii

Member
I had 2 of those sleds and I also replaced to belt guard mounted on both! I would bet the farm its the voltage regulator again!
 
H

Hoosier

Well-known member
Never ended up finding the issue before we left. I ran the main lights off the wires for the inner bulbs and that worked fine. Just didn't have low beams. Dash all works fine. Handwarmers, taillight and head light only worked occasionally. The fact they work occasionally and go out all together, and that the dash works all the time, makes me think it's a bad wire somewhere I just couldn't find. I'd think if it was the regulator, it would all go, or at least wouldn't start and stop working. I'll probably end up buying a regulator for it. I see now Poo wants $200 for them...
 
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