25 volts? are you sure?? That could be an issue.....

So you know all lights are good right? Something is likely rubbed, bare wire on metal, etc.

Might have to pull out all the wiring and redo it.

 

I'm sure about the 25 volts and all the lights work. Why? Is that too low? It's the same amount of voltage that's powering the back lights (although they are much smaller so maybe they don't require as much voltage?) I don't know. Does the fact that there's voltage coming out at all (albiet only 25 volts) a sign that it's not a fuse?

 

Update: the back lights are working again. I guess I blew a fuse. But the front light still won't go on.

 

While the LEDs are likely designed to work with most voltages, 25 seems a bit off for a RZR unless this is not a RZR?

Something is off....I would take all the wiring out and inspect it.

 

25 volts on a 12 volt system hummmmm

 

The lightbar will work fine on 24 volts. But I would if that's direct off the battery you have more problems than lightbar troubles.....you have stator/charging issues within the RZR. Which could be back feeding and popping fuses.

 

Quite honestly sounds like a ground problem.

 

It's not running directly from the battery. I just tested the light directly on the battery terminals to make sure it was working. The front and back light sets both have their own on/off switches. Here are pictures of the battery, fuse box, and relay switch if that helps at all. Thank you.

 

One more important thing to note. The wires powering the light bar are reading 25 volts but as soon as I connect the light bar to those wires, the voltage drops to about 14 volts. Is that the sign of a ground issue or a restriction somewhere in the circuit? If so, why is there 25 volts and then it drops when a load is connected?

 

Unless you have 2 batteries wired in series, I'm going to say you have voltage regulator problems or worse. You definately should not be getting 24 volts from a single 12 volt battery with the engine not running!

 

make sure your voltmeter isnt telling you mV. if you are running one 12v battery and nothing else you wont get more than 14ish volts (engine running). check your voltage at each wiring transition you should have 12 volts. going into your relay from the main power source and a 12v trigger. if you have good power going into the relay and the bar isnt coming on swap the relay with the rear one you have and i bet the light comes on.

 

have you checked the inline fuse? There should be a fuse inline on the light wiring harness.....(not inside the fusebox) I suspect you are reading 24 millivolts which is basically nothing.

Edit* that looks like an inline fuse holder near the relay in the wiring picture

 

^^^^^^^ What he said ^^^^^^^

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You're battery would be smoked if it was getting 24 volts.... and most likely all the wiring

 

Looks like the wiring for that relay is getting all its power from the low current accessory power point... hard to tell, but since there is no power wire to the battery direct post other than the winch (and the wire to the battery), where is the light bar getting its main power from? There isn’t any extra wires in the picture of the battery, so it is getting all its power from the ACC post which is low current for triggering relays, and shouldn’t be used to power the actual light bar. I can’t believe more fuses haven’t blown, but perhaps something else is now fried since your getting 24 volts, which it should never be on a 12v system.

And people wonder why RZRs burn up on the trail... [emoji23][emoji23][emoji23]


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Well, been a couple of weeks and no update... this thing burn to the ground, or did you fix the wiring and all is good? [emoji23][emoji23][emoji23]


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UPDATE
Hey, sorry for the long-overdue update. I got everything working by replacing the wiring harness and switch (got a replacement wiring harness off Amazon for like $20). I think the original problem was a loose or corroded wire somewhere downstream that was causing the voltage to drop. I was being a dummy with the voltage--I had my multimeter set to AC current, not DC. When I correctly set it to DC, it was showing 12v current (as everyone already knew). So, I appreciate everyone's help and feel good that I was able to troubleshoot and fix the problem.

 

:FIREdevil::campfire_flames_md_:flame: