I just did the 3 head light mod on my 04 sportsman 600, with the instructions below that i found on here. I know have no head lights what so ever, I douple and triple checked all my connections, and i am getting power from the 12 volt recepticale and a ground becuase the respeticale will charge my cell phone, and that every thing was hooked up the way it says in the directions. i do have a question for you all, when you splice in the wires to the relay on either the green or the yellow wires in the directions, is the green wires electricity suposed to go on its normal path and to the relay or just to the relay, i have it right now going just to the relay. any help is appreciated.

Three headlight mod- you will need a common relay from an auto parts store(I used a five pin because they are most common and came with a wiring harness), four 8" pieces of wire, and splice connectors. With the headlight pod off and the two harnesses unplugged you will need to splice the followoing wires:
#30 on relay to the green wire coming from the harness on the left handlebar
#87 to the positve wire on the lighter plug
#86 to the yellow wire coming off the top headlight harness
#85 to the lighter ground(brown wire)
Once it is all connected you should have all three lights on when switched to HI.
__________________

 

upadate... so i splied in both sides of the green and yellow wires to the relay, both grond and power are coming from the 12 volt receptical, now all lighs come on no mattter what postion the switch is in besides off. will this over power the switch on the handle bars.

 

Shouldn't hurt the switch but make sure you got the right green & yellow wires. Should be close to the headlight(high beam-pod). There are others in the pod harnesses if I remember correctly.

 

 

you should have it correct. id recheck your wires. as said. make shure you have the right dark green and yellow.

shoudnt have an issue with the switch. on my 2000 sp all i did was put the headlight switch mid way between high and low. and id have all 3 lights did this many times with out an issue.

 

this sis the way i hooked it up,works perfect,the instructions in your original post do not match this schematic.I wasnt sure what one to use,but decided to go this way after doing some research on how relays work

 

i agree with the midway on the switch, did it with my old 450 sportsman all the time.

 

newfiebullet where are you livin',I live in St.John's
I would be cautious on putting switch midway for any lenght of time,its not built to handle the extra power going through it,and it isnt cheap to replace

 

in st johns as well, from down marystown way,which unfortueately is where my bikes are haha

 

....nice looking rides.
Headin' out glenwood way on Friday for some boys and their toys time,cant wait.Hey you got to get those machines closer to you