fixed it today. heres the before pic:

 

well at least you got it fixed and now no more worries about that problem. good deal

 

your telling me. it wasnt the fixing part that was a pain. it was removing everything to get to it....

you know what they say "the only way you know its done right. is to do it your self"

all polaris had to do was route the wires though the top of the harness. then it would have been fine. but now im looking for a high beam head light plug so i can fix that also. last winter when i was trying to replace the headlight bulb i broke off one tab. but it was a 20deg day. plus there are also cracks in the wires near the base of the plug. i found the plug for $2 and its a little bit shorter. im just trying to figure out if it is the correct one. i also added dielectic grease to my plugs becuse they were starting to corode and turn green.

 

good luck w/ it chuck.

 

I've got both an '08 and '09 500 EFI. Both of them have broken the wires to the high beam headlight. The '09 three times and the '08 twice. Both are currently not working. Does anyone have a re-routing solution or something to keep them working? It's getting frustrating having them break all the time. The '09 even pulled the yellow wire apart that goes to the key switch. My '06 450 never did this and it had almost 8000 miles on it when I traded it off.

 

sounds like chuck figured a way to reroute maybe. i bet it's not easy to do for sure.

 

i ran mine though the top of the harness and gave it more slack. hopefully this will work. if not im gona have to firgure out another way. been working so far.

 

good call! check the wires coming out of the protetive wrap,, basially the chaffing of the plastic covering cut right through the yellow wire,, .. Pulled all that out of there , made a new connection and tied it back together with a little more finesse. and Voila. its a fix

 

Dbradicich, Welcome to Atv Connection, Glad you got it taken care of.

 

and another happy member from a great forum, and welcome also.