Polaris Trail Blazer, Service Manual

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10.6 Polaris Sales Inc. 4/99
ELECTRICAL
Headlamp Service - Gen lV
High Beam Headlight Adjustment (Gen IV)
The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom
right side of the headlight pod.
1. Place the vehicle on a level surface with the headlight
approximately 25’ (7.6 m) from a wall.
2. Measure the distance from the floor to the center of the
headlight and make a mark on the wall at the same height.
3. Start the engine and turn the headlight switch to high
beam.
4. Observe headlight aim. The most intense part of the
headlight beam should be aimed 2
″
(5.1 cm) below the
mark placed on the wall in step 2.
NOTE:
Rider weight
must be included on the seat. On machines with separate
low beam lights, the drop should be 8
″
(20.3 cm) in 25’
from the center of the low beam lamp.
5. Adjust beam to desired position .
Headlight Lamp Replacement (Gen IV)
CAUTION:
Do not service
while headlight is hot. Serious
burns may result.
1. Remove Phillips screw from
bottom of headlamp.
2. Remove plastic lens retaining
bracket.
3. Grasp base of bulb at back of
housing and twist. Carefully
remove bulb from housing.
4. Gently pull back locking tabs
on wire harness terminal until
base of bulb is released. Un-
plug bulb from harness.
Headlight Housing Replacement (Gen IV)
1. Remove three Phillips screws at back of headlight pod.
2. Remove Phillips screws from bottom of headlight pod at each front
corner.
NOTE:
To aid in accessing these screws, it may be helpful
to turn handlebars to left or right and use a short, stubby screwdriver.
Removal of the front rack and cover will also allow easier access.
3. Lift pod cover up. Using a pliers, disconnect speedometer cable. Un-
plug indicator lights from harness and remove pod cover.
4. Unplug headlamp from wiring harness.
5. Remove O-Ring from headlight pivot pins.
6. Pull headlight housing up to release from locking tabs.
7. Lift adjusting knob up to remove from locking tabs.
8. Carefully pull assembly up and out of pod.
9. Reverse steps to install new housing and reassemble pod.
10.Adjust headlight aim by turning adjusting knob.
25’ (7.6 m)
Lamp Center Height
2
″
(5.1 cm)
Snap pins
into tabs
Position
knob in
slot and
secure
in lock-
ing tabs
Slip O-Ring
over pin
Adjustment
Knob Stop
Speedometer
Cable
Route
plug over
handlebar
O-Ring
5 1/8
″
(13 cm)
Distance from headlamp parting
line to end of adjustment knob stop
is 5 1/8
″
(13 cm).