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.
they are verry brittle everywhere check your air breather to carb tube for cracking give it a good squeez
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