Headlamp Switch; Brake Light Switch - Polaris SPORTSMAN 400 2003 Service Manual

LOWER HEADLAMP
REMOVAL/INSTALLATION
Lower Headlamp
Turn Harness Assembly
to Remove and Install the
Headlamp
1. Turn the back of the headlight harness in a
clockwise direction.
2. Pull the harness assembly out from the headlight
assembly.
3. Remove the headlamp and replace with a new
headlamp.
4. Install the new headlamp and harness assembly
into the headlight assembly. Turn the headlight
harness counterclockwise
headlamp into place.
HEADLIGHT HOUSING REPLACMENT CONT'D
5. Pull headlight housing up to release from locking
tabs.
6. Lift adjusting knob up to remove from locking
tabs.
7. Carefully pull assembly up and out of pod.
8. Reverse steps to install new housing and
reassemble pod.
9. Adjust headlight aim by turning adjusting knob.
Distance from headlamp parting
line to end of adjustment knob stop
is 5 1/8² (13 cm).
5 1/8²
(13 cm)
TAILLIGHT/BRAKELIGHT
LAMP REPLACEMENT
If the taillight/brakelight does not work the lamp may
need to be replaced.
1. From the rear of the taillight remove two screws
2. Remove lamp and replace it with recommended
3. Reinstall the lens cover removed in step 1.
4. Test the taillight/brakelight to see it is working.

HEADLAMP SWITCH

Remove the headlight pod cover.
to secure the
headlamp plug wires (Brown and Yellow) at back of
connector. Turn headlight on.

BRAKE LIGHT SWITCH

1. Remove the front cover.
2. Disconnect wire harness from switch.
3. Connect an ohmmeter across switch contacts.
4. Apply brake at handlebar lever and check for
Lens Cover
Bulb
holding lens cover in place and remove lens
cover.
lamp. Apply Nyogelt Grease (PN 2871329).
Brown
Headlamp Plug Wires
Brake Lamp Switch
Reading should be infinite ( ).
continuity between switch contacts.
ELECTRICAL
Probe the
Yellow
Replace
10.21