Headlight Housing Replacement - Polaris Sportsman 2004 Owner's Manual

MAINTENANCE AND LUBRICATION
Lights

Headlight Housing Replacement

1. Remove the two screws on the lower front corners of the headlight
pod.
2. Using a small flat-blade screwdriver, push in on the lock tab
through the two small openings at the front of the headlight pod.
3. Lift the pod slightly while depressing the tabs.
4. Remove the screw in the back of the headlight pod.
5. Lift the pod cover. Disconnect the speedometer harnesses from the
speedometer. Unplug the indicator light harness and remove the
pod cover.
6. Unplug the headlamp from the wiring harness.
7. Pull the headlight housing up to release from the locking tabs.
8. Lift the adjusting knob up to remove from the locking tabs.
9. Carefully pull the assembly up and out of pod.
10. Reverse the steps to install the new
housing and reassemble the pod.
NOTE: The distance from the
headlamp parting line to the end of
the adjustment knob stop is 5 1/8"
(13 cm). See illustration.
11. Adjust the headlight aim by
turning the adjusting knob.
96
5 1/8"
(13 cm)