2003 Sportman 700 - I bought a 2-3 headlight conversion kit off Ebay that will basically light all 3 lights when high beam switch is on. Only problem is that after 10 or so minutes of riding, all lights, including gauge backlights go out. After less than 1 minute they'll come back on and run for another few mintues before they go out again. This cycle will keep going until I obvoiusly give up and only run on low beams. It's as if something is overheating and when it cools off, it resets itself. Any idea what this could be?

 

sound to me you have a bad relay in there some where.

 

Are there any circuit breakers on the polaris? It sounds like mabye the eccess load may trip a circuit breaker and then once it thinks the short is gone it makes the circuit again. Just a thought.

 

I bet it is your circuit breaker. It is under the front panel below the headlight pod. It looks like a black heatshrink bag. You will have to cut it open to access the 20 amp breaker. You can buy a replacement breaker at any automotive repair store. You will likely also have to replace the ring terminals as well.
I had the same problem, whenever I had my headlights on, everything would cut out for a minute or so, then come back on.
Even with the headlight mod, which I have installed, you should only be drawing approx 8 to 10 amps. No reason for a healthy circuit breaker to kick out.