Anyone out there have problems with total lights failing yet motor runs fine? My ZR600 EFI just lost all lights yet has a dim glow in center headlight bulb but other than that there is no lights upfront or rear. Tried replacing voltage regulator but not the problem, I suspect the lighting/charging coil. Before I start tear down I hoped someone might have experienced this type of problem before?? :banghead:

I've had tons of problems with voltage regulators.... on my 94 ski-doo i've gon through 3 of them, then we just bought one that was made for a 93 wildcat and put it on and its never worked better, havn't blown a bulb and havn't had to get a new voltage regulator. The first season my voltage regulator went, my dads 87 el tigre had the same problem and so did my step-dads 88 jag. It was a nightmare, mine is the only one that still works right. Don't really know a fix for it because every voltage regulator that was made for my sled that we put in didn't work right and we kept blowing bulbs. Then when we picked up the 93 wildcat regulator at my dealer for 11 bucks to put on my dads sled, it didn't work on his. We thought what the hell, put it on mine and it worked!

Unplug the main harness and check for voltage at the yellow lead, if its O.K. take off the seat/tank and examine the harness where it passes through to the engine compartment. I've fixed many where the harness is squeezed by a hose or the tank and eventually the insulation wears through, than the wires short and get warm causing more insulation to melt/fail. Another headache can be handwarmer wires shorted to the bars.

FLyntigre,

I had a similar issue with my 1999 ZL600EFI two years ago. This is what I found.

On the harness coming from the Engine there is a wire that loops between the chassis ground and frame ground. The wire loops from the connector back into the connector. You could definately tell it was a factory loop and not some idiot. Anyways, when the wire became fatigued it fractured causing all sorts of lighting issues.



Hopefully this helps

Stinno

My brother and wife's cousin had the same problem with their 02 ZR600 EFI's. Apparently the wiring harness was not routed properly. When the hood is closed. the wire harness would kink and fatigue or, come in contact with the pipe and the insulation gets burned off causing a short condidtion. This was part of a factory recall/bulletin.

My 98 ZR 6, was almost the same, the harness was pinched under the airbox right by the steering post, wore through and shorted against the top of the tunnel. Let me tell you, cruising up a road doing 90+ mph at about 11 pm is a very bad time to have your headlights go on you :frech32:

Same problem on my ZR800 last year... It was the tie wrap that held the wiring harness onto the handle bar post, I cut the tie wrap and everyting OK. Guess the wire was kinked enough that it was causing resiatance issues. In my case symptoms were lights flickering and tach erratic as I rode but engine was running fine.

My vote... check the various connnections and tie wrap points with engine running and wiggle them around to see if all of a sudden lights flicker etc. Thats how I found my issue. Otherwise start working back with a volt meter.

Eric

Anyone out there have knowledge of ZR600 98 stator & rotar problems in the past. Seems I have purchased a used knightmare with at least #3 times that stator and rotar have come apart and destoryed its self. There is obviously a reason which I am sure is a out of round crank shaft by flywheel.

My Question is does anyone remember what warrenty bulletins where issued in 1998 & 99 regarding this problem?

Just gold mining.

Picture

Problem solved - Crank was out of line causing a wobble that heated up magnets on flywheel and caused lighting coils to become damaged by magnet debree. Can rewind lighting coils x3 fairly cheap but need new flywheel. Looking for used as new is $687 canadian.