5.15
BODY / STEERING / SUSPENSION
5
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Headlight Pod Exploded View
Disassembly
• Remove two side Phillips screws (A)
• Remove one rear Phillips screw (B)
• Lift top half of pod
• Disconnect instrument cluster wire connectors
• Disconnect work light switch connector
• Disconnect 12Vdc power plug (G)
• Disconnect headlight harness
• Remove ignition switch (C) and choke cable (D)
• Remove headlight (F) with adjuster
• Remove two screws securing bottom half of pod
(E)
Assembly
• Install bottom of pod onto handlebar and secure to
brackets
• Install key switch, choke cable, and headlight
• Connect 12Vdc power outlet (where applicable)
• Connect headlight
• Connect instrument cluster connectors to
instrument cluster
• Install top of pod onto bottom half, making sure
interlocking tabs mate properly
• Install two side Phillips screws
• Install one rear Phillips screw
• To adjust headlight, refer to procedure outlined in
Chapter 2
Worklight Switch
Instrument
Cluster
A
A
F
B
C
C
E
D
Brake
Clean knurling when
repositioning handlebars
Wheel Speed Sensor - Sportsman
G
ETC
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