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Discussion Starter · #1 · (Edited)
My Rush 600 has been through a lot of problems in the past week, I'm trying to get it all figured out but I'm stumped...

First off, I keep blowing headlights. Been through 3 pairs in the past two days and both highs and lows go out at roughly the same exact time as one another. Checked all the grounds and all seem to be good. This sled did have an electric start but I took both the starter motor and battery out as I didn't use either and.... weight reduction. When checking the VR, I'm pushing 13.5v at idle and not much different when I give it throttle. Am I missing a ground? Is the battery necessary in the circuit?

Second, when I went riding today, my sled would throw a DET code and 524007:3 on the diagnostic display. This just started happening today and I'm not sure where to even start. It has fresh, non-ethanol gas in it (that's all I run). I've never had this problem before and am very confused as to why it started acting up.

Any advice on these two problems, even if they're related or not, would be much appreciated! Winters in WNY seem to be getting shorter and this storm just rolled through so I'm excited to get out and ride.

Edit: Ran some tests. The headlight sockets drop voltage when revving the motor (13v/14v @ idle down to 8v/9v). Also found a blown 2A fuse which I then replaced to no effect. I've cleaned and tested my 24 Ohm fuel resistor and that didn't solve the error code issue and I have a new VR coming in hopes this will solve my electrical problem.
 

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Discussion Starter · #3 ·
check connections on blubs if good gotta be regulator,, check spark plugs ngk been having issues, porcelain been separating
Changed both the AC and DC VR with the same issues. The spark plugs are basically brand new BPR9ES and those look okay. I'm starting to think it's the stator. I ran tests on it and it all checked out as if the stator is working and cleaned the grounds to no avail. But that's the only thing I haven't changed yet...
 

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ok ,you are getting 8/ 9 volts at the head light plug, correct , but out put of stator is 13/9, correct ,, you have a corroded, wire some where ,harness connector melted , a wire grounding out , start looking at all the harness connectors ,, while you are there apply light amounts of die electric grease, your gonna have to go on a search and find mission, might be a good chance both issues are related
 

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Discussion Starter · #11 ·
ok ,you are getting 8/ 9 volts at the head light plug, correct , but out put of stator is 13/9, correct ,, you have a corroded, wire some where ,harness connector melted , a wire grounding out , start looking at all the harness connectors ,, while you are there apply light amounts of die electric grease, your gonna have to go on a search and find mission, might be a good chance both issues are related
Been looking for days.. Even pulled all the harnesses out and went through wire by wire to see if anything is rubbed. Everything looks good, dielectric grease is on every connector on the sled. The same thing is happening. I ordered a stator Friday so it should be here within the next week. I'm no longer rushing the project, I picked up a 2017 pro s 800. I just want to fix the 2010 before I sell it
 
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