Polaris 2005 Sportsman MV7, Service Manual

Page: 147 / 312

BODY / STEERING / SUSPENSION
5.13
HEADLIGHT POD EXPLODED VIEW
Clean knurling when
repositioning handlebars
*NOTE: To install handlebars, follow
the handlebar block torque procedure
on the next page.
Disassembly
S
Remove two side Phillips screws (A).
S
Remove one rear Phillips screw (B).
S
Lift top half of pod.
S
Disconnect instrument cluster wire connectors.
S
Disconnect winch switch connector.
S
Disconnect 12V power plug (G).
S
Disconnect headlight harness.
S
Remove ignition switch (C) and choke cable (D).
S
Remove headlight (F) with adjuster.
S
Remove two screws securing bottom half of pod (E).
Assembly
S
Install bottom of pod onto handlebar and secure to brackets.
S
Install key switch, choke cable, and headlight.
S
Connect 12V power outlet (where applicable)
S
Connect headlight.
S
Connect instrument cluster connectors to instrument cluster.
S
Install top of pod onto bottom half, making sure interlocking tabs mate properly.
S
Install two side Phillips screws.
S
Install one rear Phillips screw.
S
To adjust headlight, refer to procedure outlined in Chapter 2.
S
To apply decals, refer to Page 5.23.
E
A
D
C
F
A
B
C
*NOTE: Refer to Chapter 10 for more
information on headlight pod compo-
nents.
G
Instrument Cluster
Winch Selection Switch
ETC
Brake
Controls
Wheel Speed Sensor