Polaris Outlaw 500, Service Manual

Page: 176 / 202

7.3
ELECTRICAL
7
LIGHTING AND CONTROLS
Neutral / Reverse
Position Indicator Switch Test
1. Shift the transmission into 1st gear. The ohm meter should
show no continuity or OL when testing at points A and B.
2. Check for continuity at test points A and B while in reverse
and neutral. You should have continuity on one of the wires
for each test at points A and B.
NOTE: If there is no continuity at either of the wire
connections with the transmission in neutral or
reverse, remove the switch and inspect the shift
drum contact pin and spring for proper function. If
no problems are found, inspect the wiring, bulb, and
harness connection.
Headlight Lamp Replacement
1. Remove the wire harness connector from the back of the
headlight.
2. On the left headlamp, grasp the bulb housing and turn it
counterclockwise and pull outward (1) to remove the bulb.
On the right headlamp, turn the bulb housing clockwise and
pull outward (2) to remove the bulb.
3. Apply dielectric grease to the light bulb socket before
installing the new bulb. Install the replacement bulb into
headlight housing and rotate firmly.
NOTE: The bulb must be positioned so the harness
installs into the lamp at the outer side.
4. Reinstall the connector to the back of the headlight.
Headlamp Switch Test
Probe the headlamp plug wires (Brown and Yellow) at back of
connector. Turn headlights on. Test for battery voltage across the
connections.
• Low Beam - Brown and Yellow
• High Beam - Brown and Green
If no current is found, test for bad connections, switches, or
broken wiring. Refer to the wire diagram for harness routing and
connections.
Headlight Housing Replacement
1. Remove the wire harness connector from the headlights.
2. Remove the front cab. Position the cab upside down on a
soft protective surface to prevent scratching.
3. Remove the small adjuster bracket (1) and install it on the
new lamp.
4. Remove the large pivot bracket (2) and remove the
headlamp.
5. Install the new headlamp by inserting the outboard pivot
pin in the hole of the mounting tab on the cab.
A B
RED
BLK
1
2
CAUTION
Do not service while headlight is hot. Serious
burns may result. Protect lamp during install.
1
2