High Beam Headlight Adjustment; Headlight Housing Replacement - Polaris SPORTSMAN 400 2003 Service Manual

ELECTRICAL
6. Install clear battery vent tube from vehicle to
battery vent. WARNING: Vent tube must be free
from obstructions and kinks and securely
installed. If not, battery gases could accumulate
and cause an explosion. Vent should be routed
away from frame and body to prevent contact with
electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts
the vehicle frame, corrosion will occur.
7. Route cables so they are tucked away in front and
behind battery.
HIGH BEAM HEADLIGHT
ADJUSTMENT
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.
25' (7.6 m)
Lamp Center Height
2² (5.1 cm)
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 2² (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 8² (20.3 cm) in 25' from
the center of the low beam lamp.
5. Adjust beam to desired position .
10.20
HIGH BEAM HEADLIGHT
LAMP REPLACEMENT
CAUTION: Do not service while headlight is hot.
Serious burns may result. Protect lamp during install.
Position
knob in
slot and
secure
in lock-
ing tabs
Adjustment
Knob Stop
1. Remove three Phillips screws on the headlight
pod.
2. Lift pod cover up.
3. Unplug headlamp from wiring harness.
4. Remove rubber shield from headlamp housing.
5. Push in and turn plastic retainer counter
clockwise and remove.
6. Carefully remove headlamp bulb from housing.
7. Reverse procedure to install new headlamp bulb.
HEADLIGHT HOUSING
REPLACEMENT
1. Remove three Phillips screws on the headlight
pod.
2. Lift pod cover up. Unplug speedometer from
harness. Unplug indicator lights from harness
and remove pod cover.
3. Unplug headlamp from wiring harness.
4. Remove O-Ring from headlight pivot pins.
O-Ring
Snap pins
into tabs
Slip O-Ring
over pin
Route
plug over
handlebar