Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 267 / 289

ELECTRICAL
10.39
CONVENTIONAL BATTERY
CHARGING PROCEDURE
1. Remove the battery from the ATV to prevent
damage from leaking or spilled acid during
charging.
2. Charge the battery with a charging output no
larger than 1/10 of the battery’s amp/hr rating.
Charge as needed to raise the specific gravity to
1.270 or greater.
3. Install battery in vehicle with positive terminal
toward the front. Coat threads of battery bolt with
a corrosion resistant dielectric grease.
Dielectric Grease
(PN 2871329)
4. Connect battery cables.
WARNING
To avoid the possibility of explosion, connect positive
(red) cable first and negative (black) cable last.
5. After connecting the battery cables, install the
cover on the battery and attach the hold down
strap.
6. Install clear battery vent tube from vehicle to
battery vent. WARNING: Vent tube must be free
from obstructions and kinks and securely
installed. If not, battery gases could accumulate
and cause an explosion. Vent should be routed
away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts
the vehicle frame, corrosion will occur.
7. Route cables so they are tucked away in front and
behind battery.
HEADLIGHT LAMP
REPLACEMENT
CAUTION: Do not service while headlight is hot.
Serious burns may result. Protect lamp during install.
Remove 3 screws
Snap pins
into tabs
Position
knob in
slot and
secure
in lock-
ing tabs
Adjustment
Knob Stop
Route
plug over
handlebar
1. Remove three Phillips screws on the headlight pod.
2. Lift pod cover up.
3. Unplug headlamp from wiring harness.
4. Turn bulb connector housing counter clockwise and
remove.
5. Carefully remove headlamp bulb from housing.
6. Reverse procedure to install new headlamp bulb.