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I have a 2004 sportsman 500HO. The headlights have gone out, worked then didn't. I can find no broken wires, no blown fuses. Anyone have suggestions of where to start?? It's frustrating.
 

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It depends on the date of manufacture of the quad - early or late 2004 - what's the VIN?

I suspect switches and wiring connections first, but if you have a late production model, then the SSCB (solid state circuit breaker) module may have failed. Once I know which model you have and the production date, I can provide more accurate information.
 

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As ridiculous as this may sound, using a multi-meter, are you getting any volts and the headlight plug(s)? Have you tried a new bulb? Put the multi-meter in the OHM setting, and touch each probe to the two prongs on the light bulb. If you get an OHM reading then the bulb is good. If no OHM reading, the bulb is bad.

Not likely that all headlights would blow at the same time, but if there was an electrical surge somewhere in the system, and the headlight switch was in the on position, then it could zap all the bulbs.

Start tracing it back. use a multi-meter, and test the headlight plugs. If there is no voltage there, then test the wires at the handlebar switch. If there is no voltage there, then keep tracing the wires back to either where they have voltage, or where they originate from to find the issue.

Are the taillights working when you flip the switch? Does the tail light work when you press the brake on the handlebar?
 

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It depends on the date of manufacture of the quad - early or late 2004 - what's the VIN?

I suspect switches and wiring connections first, but if you have a late production model, then the SSCB (solid state circuit breaker) module may have failed. Once I know which model you have and the production date, I can provide more accurate information.
Where is this SSCB located on these machines. my 2004.5 would have this and if they are problematic, then I might want to switch it out just to be on the safe side. Also, if the SCCB does fail, are there any other electrical components that would fail as well, or just the headlights?
 

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Registered
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9,484 Posts
It depends on the date of manufacture of the quad - early or late 2004 - what's the VIN?

I suspect switches and wiring connections first, but if you have a late production model, then the SSCB (solid state circuit breaker) module may have failed. Once I know which model you have and the production date, I can provide more accurate information.
Where is this SSCB located on these machines. my 2004.5 would have this and if they are problematic, then I might want to switch it out just to be on the safe side. Also, if the SCCB does fail, are there any other electrical components that would fail as well, or just the headlights?
The SSCB is not particularly problematic, but like any electrical component subject to failure. They cost about $340

Usually located under the front cover and mounted to the bulkhead.
 
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