I had my 2008 Polaris Sportsman 500 in the shop recently. A few months ago the headlight that is mounted on the handlebars stopped working. I did not worry about it too much, I just assumed that the bulb burned out. Then last week the engine died when I turned the handlebars to the left. I turned them back straight and it ran again. I was able to make it most of the way home like this before the engine quite and would not restart.
When I finally got it in the shop and took the handlebars and instrument cluster apart this is what I found. The lower arrow points to the broken headlight wires and the upper arrow points to the main switched power wire. A few of the other wires also had cracks in the insulation but were not broken off.
It was easy to solder the broken wires back together, but I am a little worried about future problems. For some reason the wires seem to be brittle and cracking where they move with the handlebars.