Polaris Sportsman 500 H.O. Headlight Mod

Disclaimer:  These instructions are not a full representation of the complete process of installing After-market mods. Roosting the Dunes is not liable nor takes any responsibility for improperly installed mods. This page is For information purposes ONLY.

 

Ever been trail riding in the woods at night and needed more light from your Polaris Sportsman? We have often wondered why Polaris does not allow the option for all three lights to be on at the same time.

We went in search of a commercially available mod and came across a kit that Montana Jacks called the Polaris Headlamp Improvement Kit, it sells for $19.99.

This kit consists of:

1 12 inch yellow wire
1 other wire that is green on one end and yellow on the other. The two colors are connected in the middle by an inline fuse, diode, relay or something. 
2 splice terminals
2 spade terminals
1 rocker switch

Lets get started. The first step in our installation is to determine the location of the rocker switch on the gauge pod. As you can see from figure #1, we decided to mount ours right in the middle below the speedometer. This allows us to access it easily without obstruction. 

We removed the Headlight pod by removing the three retaining screws and moved the headlight out of the way so we can get to the wiring. Locate the wiring harness (see figure #2) that houses the low beam wire (green wire) and the high beam wire (yellow wire), inside the headlight pod Use a test light to verify that these are the wires we are after.. You may have to slice both covers open to find these. 

Next we splice the Green wire from the kit to the Green wire from the harness. (see figure #3) Install the Spade terminal on the opposite end of this wire (yellow end) an push the spade terminal on the copper fug if the rocker switch.

Install the other Spade Terminal on the 12 inch piece of wire and secure it to the silver lug of the rocker switch. Splice the open end of this wire to the yellow wire in the harness using a splicing terminal. Test your lights.

This mod give us the ability to have three different lighting choices.

1. Low Beam, lower rack mount lights only.

2. High Beam, Pod light only.

3 Super High Beam, Pod light and lower rack mount lights.

There you have it. More wattage for illuminating the night.

 

Figure #1 Rocker switch location

 

Figure #2 Wiring harnesses

 

Figure #3 Wire Splices

 

Figure #4 Backside of Rocker Switch

 

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