Zl440 Guage Lights

if its just the lights, check your headlight and tail light,,, may be a voltage regulator problem.

Like puree said, check the voltage between a yellow and brown wire pretty much anywhere in the system, and it should be 12-14 Volts AC. Check the bulbs by pulling the rubber plugs out of the back of the gauge. I think they're 158 bulbs. If the bulbs are good, check the harness, especially where it goes over the pipe, or where it enters the belly pan. It does a fairly sharp turn there, and there may be a broken wire.

If the voltage is way off, high or low, replace the voltage regulator.

I've already changed a couple of bulbs in my '99 500EFI's gauges, with system voltage OK.

Sounds like bulbs to me too But check lead wire any way . It can"t be voltage reg or it would blow all bulbs.

I stand corrected,,, I didnt realize it but you did say the other bulbs do work,,, it is possible for both bulbs to go out close to the same time,,, I would check them first,,, keep it simple.

Thanks everyone for the help ....turnout to be the bulbs!!! It had been 3-4 years since I last rode at night....likely that both bulbs burned out over time.


Another ZL440 question....I notice that rarely if I squeeze the throttle from a different angle...the engine acts like it wants to cut out and stall...I have never had it stall or completely cut out though.
This does not happen often....I have heard about the throttle safety mechanism....Is that what is causing this?

I don,t think that the safety mec would do that only some times ,warm the motor up and run it at about 3000 on tack hit the kill switch or pull the safety stop cord then take a look at the plugs they should be a light tan, if no,t look at carb boots to make sure they don,t have any leaks and are tight, make sure plug wires are not acring on top of motor and change gas filter.

Thanks everyone for the help ....turnout to be the bulbs!!! It had been 3-4 years since I last rode at night....likely that both bulbs burned out over time.
Another ZL440 question....I notice that rarely if I squeeze the throttle from a different angle...the engine acts like it wants to cut out and stall...I have never had it stall or completely cut out though.
This does not happen often....I have heard about the throttle safety mechanism....Is that what is causing this?[/b]

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Try replacing the top and bottom seal on the throttle lever pivot pin.
With time they wear and could be the cause....part #0609-038....they're about a buck each.

the pieces that raceguy is talking about is the throttle safety,,,, I would bet you that thats your problem, by squeezing at a different angle, one of your washers is wore down enough that its causing it to cut out,,,, when they get bad, thats the first sign,,, and at about a buck a piece, you wont go broke if that doesnt turn out to be the problem,,,

Thanks again for the help...will be sure to try some new washers. Sounds like that would be the fix. It sure doesn't happen often, but when it does it gives you that creepy feeling hmy: ....how many miles am I from the trailer....lol

Thanks again for the help...will be sure to try some new washers. Sounds like that would be the fix. It sure doesn't happen often, but when it does it gives you that creepy feeling hmy: ....how many miles am I from the trailer....lol[/b]

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I had to take my safety thing in the throtle on my polaris and that was it, all u have to do is unplug them i would'nt buy new one's

anyways hope this helps

I had to take my safety thing in the throtle on my polaris and that was it, all u have to do is unplug them i would'nt buy new one's

anyways hope this helps[/b]

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The safety features incorporated in your snowmobile are there for a reason. they are mostly passive, but do act up now and again. Fix them properly when needed, and you can rely on them when things go south.

DO NOT DISONNECT OR DISABLE THESE FEATURES!!

The safety features incorporated in your snowmobile are there for a reason. they are mostly passive, but do act up now and again. Fix them properly when needed, and you can rely on them when things go south.

DO NOT DISONNECT OR DISABLE THESE FEATURES!![/b]

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I know of far too many people with TSS problems to justify keeping the sensor in.
If the problem is just a warn out throttle bushing, it is an inxpensive easy fix, but often the sensor itself acts up and needs to be replaced.
I have personally bypassed this sensor by soldering the input/output wires together.
Arctic cat's are notorious for these things acting up

I say fix it to ,safety switchs and things are there for a reason, and think of the person you may sell it to someday it could be a new snowmobiler a kid or older person like me!