Disconnected headlight problem

RPyfz450 · May 21, 2004

I disconnected the headlights on my 450 and covered the open connectors with plastic and electrical tape. The last two times I washed the ATV with a power washer, I found the electric starter would come on and stay on whenever the ignition key was turned on. It was as if the "start" button was stuck in the depressed position. After some troubleshooting, I disvovered the problem was caused by water getting into my open headlight connector (left side). It grounds out the circuit that engergizes the low current side of the relay.

So, does anybody have any good advice on how to water proof these open connectors? I wish it could buy dummy plugs that would plug in there.

desertbound · May 21, 2004

I thought the lights were wired directly to the stator. I don't see how that could cause a problem with the starter.

Amergin · May 22, 2004

Originally posted by desertbound@May 21 2004, 02:14 PM
I thought the lights were wired directly to the stator. I don't see how that could cause a problem with the starter.

True, but they are also wired to the same switch assembly. Does everything in the stock switch share the same ground? Guess I'll have to break out the diagram and look. Still seems odd though.

RPyfz450 · May 22, 2004

You're right, it's hard to see the connection between the headlight connectors and the start circuit.

Once I found the circuit that was improperly shorted to ground, I put a continuity test between it and ground. While listening to the beep of the multimeter I began wiggling wires unil the short to ground became intermittent. This is what lead me to the left front headlight connector.

I will double check my diagnosis, since I looked at the diagram and I am having doubts I found the source of the short.

Disconnected headlight problem

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