2003 Polaris Sportsman 600 Owners Manual - Page 101
2003 Polaris Sportsman 600 Manual
Page 101 highlights
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 1 speedometer harnesses from the speedometer. Unplug the indicator light harness and remove the pod cover. 6. Unplug the headlamp from the wiring harness. 7. Remove the o-ring (1) from the headlight pivot pins. 8. Pull the headlight housing up to release from the locking tabs. 9. Lift the adjusting knob up to remove 5 1/8″ from the locking tabs. (13 cm) 10. Carefully pull the assembly up and out of pod. 11. 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. 12. Adjust the headlight aim by turning the adjusting knob. 99
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