My headlights on my 02 400 sportsman begin to click on and off after they have been used for a period of time. Kinda annoying in the dark ... but i shut em off have a smoke and they work for awhile again sometimes don't go out again, other times about half hour or so. Any ideas where i should start looking? Thanks

 

i am having the exact same problem with my 02 sportsman 400. i posted a thread a couple of weeks ago and no replies, hopefully someone comes up with a fix. when your lights go on and off can you hear a clicking sound coming from the front of the quad (just under the rad cover)????

 

Yes i sure can...

 

i treid earlier to see if i could find a relay in the parts break down but i didnt see one w/ a quick check but it sounds like a relay is going bad if you hear clicking.

 

The tech manual shows a 10 amp circuit breaker in the harness for the headlights(low beam) It could do exactly what your talking about(including the clicking noise)

Polaris usually puts the circuit breakers in unaccessable plastic covers and melt the ends together. Cut it open and check it when the problem occurs and i bet you will find your problem.

 

does that relay include the high beams also?? both my low and high beam click on and off!!

 

While looking at the diagram I must have gotten off the wire I needed and got onto the fan circuit and thats the wire that goes to the circuit breaker. Sorry about the wrong info. I try to check this stuff out at work and try to hurry so I must have just been going too fast.

I'll do some more checking at break.

 

ok i found out where the clicking noise is coming from, there is a solenoid that is attached to wires for the winch and there are red and brown wires that are conected to two prongs on the top of the solenoid, but i dont know where the go or what they do, if anyone has an idea it wuld be appreciated