Headlight Bulb Filament Continuity Test; Hi/Lo Beam Switch Testing; Seat Harness Troubleshooting - Polaris 2003 Pro X Service Manual

Headlight Bulb Filament Continuity Test

1. Turn the Multitester dial to the ohms ( ) position.
2. Disconnect the wire harness from the headlight bulb.
3. Viewing the back of the bulb with the terminal blades at
the 9, 12 and 3 o'clock position, connect the black
multitester lead to the 9 o'clock blade.
4. Touch the red tester lead to the 12 o'clock terminal and
then to the 3 o'clock terminal, noting the resistance
value of each. A reading of between 2 and 5 ohms is
good. An open reading indicates a bad element.

Hi/Lo Beam Switch Testing

1. Set the multitester dial to the ohms ( ) position.
2. If the Hi/Lo switch has not been removed from the
machine, disconnect the switch to harness plug-in
connector.
3. With the Hi/Lo switch in the Lo beam position, check the
resistance between the yellow and the green switch
wires. The reading should be less than .4 ohms.
4. Turn the Hi/Lo switch to the Hi beam position and the
multitester should indicate an open circuit (OL)
reading.
5. Move one of the tester leads from the green to the red
switch wire. The multitester should now read less than
.4 ohms.
6. Turn the Hi/Lo Switch back to the Lo beam position and
the meter should again read an open circuit (OL).

Seat Harness Troubleshooting

1. Remove the taillight lens.
2. Remove the two taillight bulbs and the brakelight bulb.
3. Separate the seat harness from the main harness by
unplugging the connector at the right rear of the tank.
4. With the multitester dial set on ohms ( ) connect either
meter test lead to the brown seat harness wire.
5. Touch the other tester lead to first the yellow wire and
then the orange wire. Observe the readings. Readings
other than an open circuit (O.L.) indicate a shorted
harness or bulb socket. NOTE: The bulb socket tangs
sometimes short to ground with the bulb removed.
6. Check between the yellow and orange wires in the
same manner to check for a short between the brake
and running lights. If damaged wiring is found, remove
the seat.
7. Tip the seat over and remove the right side seat cover
staples. Locate and repair the harness problem.
8. Reinstall the staples and re-check the seat harness.
ELECTRICAL
Low High
D
Grn
D
D
Yel
Yel/Rd D
High/Low Switch
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