The Pro Sport HID line has been discontinued. KC no longer manufactures or sells replacement components through standard retail channels. However, the Pro Sport HID was built around a serviceable design — the bulb, lens/reflector assembly, bezel, and seals are all field-replaceable.
This article covers what fails, how to identify it, the correct KC part numbers for each model, and where to source compatible components.
Understanding the Pro Sport HID design
The Pro Sport HID is fully self-contained. Unlike many aftermarket HID kits that mount the ballast externally, the 35-watt solid-state ballast and starter are built inside the Polymax housing. There is no external ballast box to replace. If the ballast fails, repair options are limited — but the bulb, optics, and seals can all be serviced individually.
Field-serviceable components:
- Bulb
- Lens/reflector assembly
- Bezel
- Lens gasket and O-ring (8" models only)
The ballast and starter are integrated into the housing and are not separately serviceable or user-replaceable.
KC part numbers by model
Identify your model from the part number on the housing, then use the tables below to find the correct replacement parts. The bulb (Part #2603) and bezel sizes are shared within each housing size.
6" Spot — Pair #640 / Single #1640
| Component | KC Part # |
|---|---|
| Bulb (shared) | 2603 |
| Lens/Reflector | 42131 |
| Bezel (shared) | 3619 |
| Lens Gasket (shared) | 3077I |
| O-Ring | n/a |
6" Driving — Pair #641 / Single #1641
| Component | KC Part # |
|---|---|
| Bulb (shared) | 2603 |
| Lens/Reflector | 42052 |
| Bezel (shared) | 3619 |
| Lens Gasket (shared) | 3077I |
| O-Ring | n/a |
8" Spot — Pair #850 / Single #1850
| Component | KC Part # |
|---|---|
| Bulb (shared) | 2603 |
| Lens/Reflector | 42102 |
| Bezel (shared) | 3618 |
| Lens Gasket (shared) | 3077P |
| O-Ring (shared) | 3077N |
8" Driving — Pair #851 / Single #1851
| Component | KC Part # |
|---|---|
| Bulb (shared) | 2603 |
| Lens/Reflector | 42032 |
| Bezel (shared) | 3618 |
| Lens Gasket (shared) | 3077P |
| O-Ring (shared) | 3077N |
"Shared" means the part is common across both beam patterns within that housing size.
What fails and how to diagnose it
Bulb (Part #2603) — most common failure
Symptoms: one light won't turn on, a noticeable color difference between the two lights (one appears yellower or significantly dimmer), or flickering that doesn't stabilize after warm-up.
Always replace bulbs in pairs. Even if only one has failed, the other has similar hours and age. Mismatched bulbs produce uneven color and output.
Lens/reflector assembly
The lens/reflector is a matched optical unit — replace the whole assembly, not the lens alone. The 8" Pro Sport HID uses a hard-coated Lexan lens; the 6" model uses glass. If the reflector appears dull, cloudy, or pitted, or the lens is cracked or deeply scratched, replace the full assembly.
Lens gasket and O-ring
Symptoms: moisture fogging inside the lens, or visible corrosion on internal components. Inspect seals any time the housing is opened for service, and replace them as a precaution on older or high-hour lights. 8" models have both a lens gasket and an O-ring; 6" models use the gasket only.
Ballast/starter (integrated — not user-serviceable)
If the light produces no output with a confirmed good bulb and a functional wiring harness and relay, the integrated ballast or starter may have failed. These are built into the housing and cannot be replaced independently. Contact KC HiLiTES directly, or see the LED upgrade option below for 6" models.
Sourcing replacement components
Start here: KC HiLiTES directly
Even for discontinued products, KC sometimes maintains parts inventory or can direct you to a service partner. Contact them with your model number and the KC part number from the table above. Stock availability is not guaranteed.
KC HiLiTES, Inc. 2843 West Avenida de Luces, Williams, Arizona 86046 Phone: 928-635-2607 Email: info@kchilites.com Website: kchilites.com
Third-party sources
Search using the KC part number directly — many off-road parts suppliers cross-reference KC components.
The Retrofit Source (theretrofitsource.com) — specializes in auxiliary and off-road lighting components. Good source for HID bulbs compatible with the Pro Sport system and replacement relay wiring harnesses.
Amazon and eBay — search KC HiLiTES part numbers directly (e.g. "KC HiLiTES 2603" for the bulb, "KC HiLiTES 42131" for the 6" Spot lens/reflector). Verify seller reputation and confirm the exact part number match before purchasing.
Off-road forums and community marketplaces — communities like PiratE4x4, Expedition Portal, and IH8MUD often have members parting out rigs with intact Pro Sport HID systems. Frequently the most reliable source for discontinued KC components.
Disclaimer: These are independent third-party sources. KC HiLiTES does not operate or endorse these retailers. Always confirm part number compatibility before purchasing.
Wiring harnesses
Pro Sport HID pair packs originally included a pre-terminated relay wiring harness. If yours has deteriorated or been damaged, two options are available:
- Part #95602 — HID-specific relay harness designed for two HID lights. The correct harness for Pro Sport HID pair setups.
- Part #6315 — General-purpose 40-amp relay harness kit. Works with Pro Sport HID and remains in current KC production.
LED upgrade path: KC Gravity LED Insert (6" models only)
If your 6" Pro Sport HID housing is in good condition but the ballast or starter has failed — or if you want to transition to LED — KC designed the Gravity LED Insert as a direct drop-in replacement for 6" Pro Sport and Daylighter housings. Your existing Polymax housing, bezel, and mounting hardware are retained.
Note: there is no equivalent drop-in LED insert for 8" Pro Sport HID models.
| Model | Single # | Pair # | Watts | Lumens | Candela |
|---|---|---|---|---|---|
| 6" Gravity LED Insert — Spot | 42133 | 42134 | 20W | 2,104 | 210,495 |
| 6" Gravity LED Insert — Spread | 42053 | 42054 | 20W | 2,104 | 126,727 |
What you gain:
- Plug-and-play drop-in — no rewiring required
- Instant-on, no warm-up period
- IP68 rated (improved moisture protection over original)
- 20W vs. 35W draw — lower electrical load if running multiple lights
- No bulb, ballast, or starter to replace going forward
What to know before ordering:
- Rated output is 2,104 lumens vs. the Pro Sport HID's 3,500 lumens. GRD optics focus output efficiently — the 210,495 candela Spot figure reflects real-world beam performance.
- Available for 6" housings only. There is no 8" equivalent.
- The Spread beam pattern is not the same as the original HID Driving beam pattern.
Available directly from KC HiLiTES at kchilites.com and through authorized KC dealers.
Troubleshooting quick reference
| Symptom | Likely cause | Action |
|---|---|---|
| One light won't turn on | Bulb failure | Replace bulb #2603 — replace both as a pair |
| Both lights won't turn on | Wiring, relay, or fuse failure | Check fuse and relay harness before suspecting the lights |
| Light flickers, then stabilizes | Normal HID warm-up | No action needed — 3–5 sec ramp-up is expected |
| Flickering that won't stabilize | Bulb nearing end of life | Replace bulb pair #2603 |
| One light noticeably yellower or dimmer | Bulb aging mismatch | Replace both bulbs as a pair #2603 |
| Moisture fogging inside lens | Gasket failure | Replace gasket: 3077I (6") or 3077P (8"); also check O-ring 3077N on 8" models |
| Cracked or scratched lens | Physical damage | Replace lens/reflector assembly — see part number table above |
| No output, wiring checks out | Ballast/starter failure | Contact KC HiLiTES; consider Gravity LED Insert upgrade for 6" models |
Related: HID vs. LED — Which technology is right for your off-road auxiliary lighting?
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