[Scott4700]

I have a electrical issue with my headlights and would like to have more experienced input, I have a 2011 Honda rancher with 500 miles on it and the headlights are acting up, here’s how. My lights are always on when I turn the key on regardless of the position of the yellow on/off switch. When I turn the yellow switch to the on position it turns on the cluster light and hi-beams if the upper switch is in low beam, if I changer the upper switch to go-beam it turns the lights to low beam, another issue with it is if the yellow switch is in the “off position” and I turn on the low beams with the upper switch the dash lights will then come on. If I could please have some help, please and thank you

 

[retro]

It sounds like the handlebar switches assembly might have failed. Refer to the attached image to test each switch position and report back with your findings if you can.

Welcome to the forums!

 

[SamUK]

As retro has said, it sounds like a faulty switch. Have you tried cleaning it with contact cleaner or a light penetrating oil such as WD40?
I’ve had a few switches now that required cleaning, the above usually does the trick.

 

[Scott4700]

Thank you retro and samUK, I will clean all of the switches and check connections and get back to you two.

 

[Scott4700]

I checked all of the connections and the switches, the switches look and preform as they should and the connection is great, could it possibly be a faulty harness from the plug to the bars?

 

[SamUK]

I checked all of the connections and the switches, the switches look and preform as they should and the connection is great, could it possibly be a faulty harness from the plug to the bars?

It could be. Have you checked all connections and cleaned accordingly? Before tearing into the harness I would use an ohmeter and see if you have power, start at the switch working your way to the lights, you’ll find out pretty quickly where the issue is.

 

[Scott4700]

Would it be too difficult or do they have a full replacement harness from the thumb control to the plug?

 

[SamUK]

Yes, that small part of harness plugs in near the steering stem and is part of the switch, comes as a complete unit. It would be a lot cheaper to check first though, all you have to do is see if you have power to the switch and power from the switch, if you have those then follow the power from the switch working your way closer to the headlights. Remeber to check your ground wires while your at it.

If you decide to buy new, don’t buy from eBay or amazon, odds on you’ll be buying a Chinese item and will end up with the same issue. Buy OEM or a good used part from PSN.

 

[Scott4700]

I have found a whole new thumb assembly/ harness (oem part) for $65 should I buy this instead of messing with the old harness and potentially messing it up

 

[shadetree]

I have found a whole new thumb assembly/ harness (oem part) for $65 should I buy this instead of messing with the old harness and potentially messing it up

number #3, $ 63.01 here ---> https://www.partzilla.com/catalog/honda/atv/2011/trx420fe-a/handle-lever-switch-cable . plus shipping of course.

 

[Scott4700]

@SamUK I was going through trails last night and ended up wheeling my quad and my lights flashed when I touched down and I didn’t think anything of it and a little later on the ride I went to turn on my low beams (headlight off position) and my lights shut off and started working as they should, I’m not sure what happened. Could have been a loose wire or bad connection to one of the headlights

 

[SamUK]

It sounds like it could be a faulty switch or as you say a loose connection, I’d give them a good clean again and make sure all plugs fit together nice and firm. You could add dielectric grease to all of your connections too.

 

[Scott4700]

@SamUK my phone won’t let me start a new thread but I was wondering if you knew anything about a locker for the quads, I’m trying to figure out the difference between these products and which one would be better, thank you in advance!

 

[SamUK]

I’m not sure a locker is available aftermarket for a Rancher, as far as I’m aware the only options you have are to modify the one you have or modify your Rancher to fit a foreman diff. Both jobs where you need to be confident in your mechanical abilities.

 

[retro]

Highlifter sells a thick plate that apparently replaces the cone spring, which locks the stock cams up.

https://www.highlifter.com/atv-lockers/honda-trax-lock-spool-locker-lckhonda-1.asp

 

[SamUK]

Always something to learn on this forum Thanks @retro

 

[Scott4700]

Thank you @retro and @SamUK , would the riser plate work for my 2011 Honda rancher 420 es?

 

[retro]

According to the application list in that Highlifter link the plate fits your bike. I've never used one before, so I suspect that it just takes up enough space to lock up the stock cams in the diff. Those types of DIY mods have been in use for years. Some folks just add cone spring washers or shim them tight with thick washers. While it is not a true locker in the purest sense of the term, it does work if it is done well. And the mod should be reversible if the person ever decided to put it back to stock.

It would be a good idea to read the front diff section in the service manual before teardown... you'll need some decent tools and a thorough understanding of how/why it works. It is important to maintain clearances/relationship between the ring gear and pinion in there. Let us know how it goes if you decide to install one..?

 

[Jeepwm69]

And doing that mod will make your bike hard as crap to steer.....

 

[SamUK]

And doing that mod will make your bike hard as crap to steer.....

Indeed it will!! It’s manageable for the first few hours but wait until you wake up the next day, you’ll feel like you’ve been in the gym for a week!

Ask me how I know! LOL.