02 Sportsman 500 HO
New battery, cooling problem solved now a short. Was out last night and noticed my lights going out and coming back on at random. I have replaced the relay so I thought it might be lose. Looked at it today and all was fine. I pulled the pod cover off just to see if there was something lose in there. Key on, no speedo lights or headlights. I just moved some wires and they came right back on. I pulled the key out since that seems to be the trigger when I wiggle those wires. Cleaned up real good and added dialectic grease. Seemed OK till I buttoned it all back up and no lights. No started either. Pull start works fine and quad runs as it should. Can these key switches go bad? I was just moving the wires around and could get it to cut out and then return. I have not looked at it for to long, but either wires or the switch. Has anyone had this happen to them? Anything else I should be checking?
Thank you
Paul P.

 

yes the switch does go bad. had a few on here that had to chnage out the switch. sounds like bad ground,loose wire as mentioned, if wiggling makes it go out or come back on maybe it could be that. just make sure when you start the bike it is still charging as you don't want to be running just off the battery.

 

Only when I wiggle the wires directly from the key switch. That is why I'm thinking the switch. Wouldn't think a wire would get rubbed bare there, but I'll check. Where is a good place to get a switch?

 

Part #4012164 (changes from old # 4010390) at Cycle Parts Warehouse ($46) Cheaper than the dealers OR you can take a chance on e-bay for a used one. I would check the wiring first! OPT

 

OPT,
Is there a way to test the key switch? I'm tired of chasing problems by buying new parts.
Thank you
Paul

 

Have had a few bad switches as mentioned,but you can have the switch ohmed out to eliminate it. But if you haven't checked the switch wiring into the harness,this is where a lot of problems were because of the twisting and turning. OPT