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MAINTENANCE
Headlight Lamp Replacement
Xplorer 400, Sportsman 500, Magnum 500
1.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 may also allow easier access.
2.Remove three Phillips screws at back of headlight pod.
3.Lift pod cover up. Disconnect speedometer harnesses from speedometer. Un-
plug indicator light harness and remove pod cover.
4.Unplug headlamp from wiring harness.
5.Remove boot and locking collar from back of lamp housing.
6.Grasp base of lamp and lift it out.
7.Reverse previous steps to replace lamp and reassemble pod. Make sure tab
on lamp locks into place in housing.
High Beam Headlight Adjustment
The headlight beam can be adjusted to any position desired by turning the adjust-
ing 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.
5.Adjust beam to desired position by turning the adjustment knob.
Snap pins
into tabs
Position
knob in
slot and
secure in
locking
tabs
Slip O-Ring
over pin
Adjustment
Knob Stop
Route plug
over
handlebar
