I have a 2006 Polaris Sportsman 450 that started having an issue with the kill switch (which I never use.) I took it apart to see what was going on and discovered that one of the contacts (there are two springy metal pieces that make contact to a control board) had melted the plastic around it and was not allowing it to spring forward and make contact. My first question for you all is why do you think it melted? My next question is where can I buy a new switch. I went to the parts store and found out that I have to buy the entire control assembly for $75. All I want is the little red plastic piece. They use the same piece on all their machines so I was hoping I could find on on a salvage or something but there is no salvage yard in my area.

 

has the ecm been replaced on that bike yet? just wondering as it sounds like a overcharge of power to it or it has a bare bike shorting out making it hot? just a guess. did you try ebay for the parts?

 

I had that apart in my Sp 450 also........They build up with dust and dirt and the contacts will arc and cause some heat there.
I took my apart over the grass were the Quad was parked.....Big mistake.....Dropped the small little spring and ***** to lock in place when moved ..Took forever to find them...........Use a pick-up magnet ........
Good luck.I never want to take that apart again.........Caper.........

 

Ya I dropped that ball also but was luck enough to hear it drop and find it on my foot rest.

The recall work has been done. I have added a switch to allow all the lights to be on at the same time. I bought the kit from Montana Jacks. Could that be what caused the part to melt?

I did check Ebay, but all I found was the hole control assembly for around $30. I may have to go that route but I was hoping I could just buy the little plastic piece for a couple bucks.

 

I don't think you are going to have any luck finding just that little plastic part...................30.00 sounds great for the whole part...........I would go that route instead of the dealer ........As for the 3-light mod........

You current going through your high/low beam switch is now higher than factory specs...........Some riders install a relay so the switch just turns that on and the high current is on the relay contacts instead of the factory polaris switch....
....Caper..........