I’ve got an older Polaris Pro-X that keeps melting the high-beam switch. I haven’t installed higher powered headlights or anything, but it has happened so many times that I now carry a spare switch with me where ever I go. Any suggestions?
I would suspect a pinched wire somewhere. One of the headlight power leads could be contacting ground, and then there’s a whole bunch of current going through that little switch. That’s been the cause of most melted headlight switches that I’m aware of. Inspect the wiring from the switch all the way to the headlights, somewhere somehow you’re getting too much current through that switch, with the result being a meltdown.
Less likely would be a design issue where the exact style switch isn’t able to carry the amount of current going through it for extended periods of time. It might be curious to see what kind of voltage (pressure) you are getting from the regulator, but the problem is likely due to the current (flow) and not the voltage.