Dimmer Switch Fix

I have repaired the brake switch on my 2000 XC500SP. The contacts were 'dirty' and I was able to take the switch apart carefully and clean it using crocus cloth. A new switch was $50+ and I thought it was worth a try to repair the old one. The repaired switch lasted for another year when I traded in the sled.

My advice is take it easy removing the old one and take care disassembling the switch. Check it with an Ohm meter or battery and a light before cleaning the contacts. I had to drill the rivets and put it back together with small brass bolts. Check for proper operation before reassembling and your good to go.


Good luck.
John.

Just curious, but how did you troubleshoot the problem to isolate a failed dimmer switch?

How many volts AC is your electrical system putting-out? (at about 3000 RPM?)

Just curious, but how did you troubleshoot the problem to isolate a failed dimmer switch?

How many volts AC is your electrical system putting-out? (at about 3000 RPM?)[/b]

Click to expand...

I used a ohm meter to check for continuity at the plug going to the dimmer switch. With the wiring diagram to the sled i could tell which wire was incomuig power wnd which ones were hi and low beam. I check voltage an I had a constant 13.5 volts. With some more research I found out Polaris had some problem dimmer switches.

Interesting.

Have you checked with Polaris to see if they put out any technical bulletins on the subject? If they had problems with their switches, there might be a "better" replacement available. If so, I would replace the switch. If the switch design won't handle the current put through it, it will only fail again, usually when you need it most.

i just replaced mine.129.00.and they had it in stock.said that its common problem!!

Yep, that sounds like my experience. As cheap as they seemed to be, the older style flipper switch was definitely less problematic as well as cheaper to replace. When I discovered how expensive a new switch block was, I decided to simply bridge the low beam contacts in the switch and go with that. It's worked for almost two years now. (Now if I can only keep my generator [engine] going, maybe I'll have lights, even if only low beam!)

i had mine soldered over for low beam but started having trouble with grip heaters and was going way north.so i changed it.now theres one on ebay.

We have 6 machines in the same category. Unfortunately we all have the same problem, Some hav only Hi the others have Lo. Obviously it is a Manufactureres defect. Would like to know if this is practical to repair????