Headlight Pod Exploded View - Polaris SPORTSMAN 600 Service Manual

HEADLIGHT POD
EXPLODED VIEW
**Thumb Warmer Switch
** Models w/ thumb warmer
and hand warmer standard. (See
Chapter 10 for more details)
Disassembly
G Remove two side Phillips screws (A).
G Remove one rear Phillips screw (B).
G Lift top half of pod.
G Disconnect speedometer wire connectors.
G Disconnect oil indicator light wires and gear
position indicator connector.
G Disconnect 12V power plug (where applicable).
G Disconnect headlight harness.
G Remove ignition switch (C) and choke cable (D).
G Remove headlight with adjuster.
G Remove two screws securing bottom
half of pod (E).
Assembly
G Install bottom of pod onto handlebar and secure to brackets.
G Install key switch, choke cable, and headlight.
G Connect 12V power outlet (where applicable)
G Connect headlight.
G Connect speedometer connectors to speedometer.
G Install top of pod onto bottom half, making sure interlocking tabs mate properly.
G Install two side Phillips screws.
G Install one rear Phillips screw.
G To adjust headlight, refer to procedure outlined in Maintenance chapter.
G To apply decals, refer to Page 5.15.
5.8
BODY / STEERING / SUSPENSION
**Hand Warmer Switch
B
A
C
Torque bolts evenly so gap
is equal at front and rear of
handlebar block
11-13 ft. lbs.
(15-18 Nm)
A
Clean knurling when
repositioning handlebars
E
D
Handlebar clamp torque:
11-13 ft. lbs. (15-18 Nm)
Adjuster