hey all my new problem is on my 400ex every time i try to go from high beam to low beam i blow my fuse i took the switch apart and cleaned the three contacts inside with a piece of sandpaper , traced the wires to the head light and found a hack job connection on all three wires repaired that , looked for any other defects and found none so now im lost any suggestions will be greatly appreciated

 

I know you don't want to hear this but there's still a bad spot somewhere and it's grounding out. Are you able to trace each wire individually or are they in a "loom"? Is there a place in the wiring that has been mashed or kinked or something like that. That could allow a break in the insulation and the high beam wire is grounding out on another wire or on some metal. Hope you find it quick. Sometimes these electrical gremlins can be a bear.

 

i traced them 2 the headlights and then from there the brown one takes off to the taillight i did not chase it but will give it a shot thanks for the help

 

You could have a break inside the "loom" with two wires grounding out. I hate electrical problems. Dad has a couple old grain trucks that are truly a joy to work with regarding lights. Nothing can make you pull your hair out more than trying to find a bad connection/ground/etc somewhere.

 

I have a 2003 400ex and soon after having it I had the same problem, mine was still under warranty so i took it in and was told that it had to do with the light wires grounding, trace the wires like ktk said and you will probably find the problem.

 

I also had the same problem one night when i was out night riding with a group of friends. Really sucked we had to push start it all night. Took it back to dealer and they told me the same ole thing.