2014 Sportsman 400 HO - No Lights

[seacoast603]

2014 Polaris Sportsman 400 HO

We had an issue with the lights working on occasion.  Then they just stopped working completely (front and rear). We looked at the EFI fuse and it was melted, but not blown.  We replaced the fuse, but now the ignition will not turn on UNLESS we pull the fuse out...and BTW, the lights still didn't work with the new fuse. Any help would be appreciated. Thanks!

Edited July 9, 2019 by seacoast603
added machine info

[quadmaniac]

The fact that the fuse melted tells me there's a short somewhere. Do you have a manual with a wiring schematic? Where the fuse melted, start tracing that wiring to see what could have caused it.

[seacoast603]

9 hours ago, quadmaniac said:

The fact that the fuse melted tells me there's a short somewhere. Do you have a manual with a wiring schematic? Where the fuse melted, start tracing that wiring to see what could have caused it.

I thought the same thing.  However, I found that when I pull the relay out. The lights work fine. Is it  possible it's just a bad relay?

[Frank Angerano]

Try this.  Leave the key on and pull the relay. See if the relay clicks when you pull it.  If so then the relay is working.  Or just touch the relay and see if it clicks when you turn the key on.   

What I would do next is trace the wire that feeds the lights and disconnect it. See if that changes anything. Does that bike have a digital screen on it ? Any codes ?

[quadmaniac]

13 hours ago, seacoast603 said:

I thought the same thing.  However, I found that when I pull the relay out. The lights work fine. Is it  possible it's just a bad relay?

Could be

13 hours ago, Frank Angerano said:

Try this.  Leave the key on and pull the relay. See if the relay clicks when you pull it.  If so then the relay is working.  Or just touch the relay and see if it clicks when you turn the key on.   

What I would do next is trace the wire that feeds the lights and disconnect it. See if that changes anything. Does that bike have a digital screen on it ? Any codes ?

Do what @Frank Angerano mentions, see if the relay is working.

[Frank Angerano]

Do you feel the relay clicking when you turn the key on and off?