Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 268 / 289

ELECTRICAL
10.40
LOWER HEADLAMP
REMOVAL/INSTALLATION
Turn Harness Assembly
Lower Headlamps
Loosen
Tighten
Headlamp
Adjustments
1. Turn the back of the headlight harness in a
counter--clockwise direction to loosen.
2. Pull the harness assembly out from the headlight
assembly.
3. Remove the headlamp and replace with a new
headlamp.
4. Install the new headlamp and harness assembly
into the headlight assembly. Turn the headlight
harness clockwise to secure the headlamp into
place.
Lower Headlamp Adjustment
5. Loosen the nuts that secure the lower headlamps.
Adjust the headlamps as needed.
6. Tighten the nuts on the headlamps after
adjustment is made.
TAILLIGHT/BRAKELIGHT
LAMP REPLACEMENT
If the taillight/brakelight does not work the lamp may
need to be replaced.
Lens Cover
Bulb
1. From the rear of the taillight remove two screws
holding lens cover in place and remove lens
cover.
2. Remove lamp and replace it with recommended
lamp. Apply Nyogel
t
Grease (PN 2871329) .
3. Test the taillight/brakelight to see it is working.
4. Reinstall the lens cover removed in step 1.
BRAKE LIGHT SWITCH
1. Remove the front cover.
Brake Lamp Switch
2. Disconnect wire harness from switch.
3. Connect an ohmmeter across switch contacts.
Reading should be infinite (
∞
).
Brake Switch Locations: Un-
der front cover close to CDI
box.
4. Apply brake at handlebar lever and check for
continuity between switch contacts. Replace
switch if there is no continuity or greater than .5
ohms resistance when the brake is applied with
slight pressure.