Required Tools and Supplies
- 8mm Socket
- T25 TORX® Socket
- 1/4-inch (6mm) Drill Bit
- Pliers (Side Cutting)
- Safety Glasses
- Nitrile Gloves
- Shop Rags
To learn more about tools, read the Tools and Fasteners Guide.
Always wear safety glasses and nitrile gloves when servicing your Polaris snowmobile. To install and operate the Auxiliary Light Kit on your Polaris snowmobile, follow these steps:
1. Begin by parking the vehicle on a flat and level surface. Set the parking brake and remove the key.
2. Remove the windshield, if equipped, by pulling the retainers straight out firmly on the top and working towards the middle until the windshield is free.
3. Remove both side panels by turning the three (3) quarter-turn latches. Pivot the panels away from the sled and pull out to remove.
4. Disconnect the two hood latches.
5. Lift the hood up slightly to gain access to the connector underneath. Disconnect the connector.
6. Pull the sides of the hood out and away from the side panel fasteners.
7. Lift the hood up and away to remove it from the vehicle.
8. Identify the type of headlight on your snowmobile. Note: Snowmobiles equipped with a NightBlade headlight will require headlight removal before installation of the auxiliary lights. Headlight removal is not required on snowmobiles equipped with a standard headlight.
9. If equipped with a NightBlade headlight, disconnect the headlight wiring, remove the three screws retaining the headlight assembly and pull the headlight assembly back and up to remove it from the hood.
10. Remove the two side trim screws with a T25 TORX® socket. Then, remove the side trim.
11. Locate the template printed on the box flap. Cut out the template.
12. Align the template along the edges of the hood and mark the drill location with a punch.
13. Carefully drill the hole on the mark with the 1/4-inch (6mm) drill bit.
14. Do this on both sides using the same template.
15. Feed the wiring through the opening in the hood while installing the new light assembly.
16. Attach the auxiliary light using the provided tool and two screws. Use the existing hole and drilled hole. Tighten the screws until fully seated. Repeat on the other side. Note: Do not over tighten screws.
17. Position the headlight assembly on the hood.
18. Attach the headlight assembly using the three screws. Note: Make sure the wires do not get pinched when installing the headlight.
19. Measure 1/2 inch down from the edge of the hood molding, and then 1/2 inch over and mark the location. Carefully drill a 1/4-inch hole in this location. Note: Remove any accessory bags or items from the storage compartment before drilling hole.
20. Attach the high-beam relay on the auxiliary wiring harness in the drilled hole using the push pin clip on the connector.
21. Attach the auxiliary harness to the existing wiring harness.
22. Attach the auxiliary harness to the headlight connection on the snowmobile.
23. Remove the tape and protective cap from the existing power connection on the snowmobile.
24. Connect the auxiliary harness power to the power on the snowmobile.
25. Connect the two auxiliary light connectors to the auxiliary lights.
26. Reinstall the hood panel, ensuring the tabs in front are properly engaged.
27. Reconnect the connector underneath the hood, and verify it is secure.
28. Continue by securing the two hood panel latches.
29. Reinstall both side panels by inserting the upper tab and pivoting in to engage the lower tab. Latch the three (3) quarter-turn latches to secure each panel.
30. Reinstall the windshield by ensuring the mounting tabs align with the mounting slots on the hood. Then, firmly press in on all tabs - firmly working front to back to ensure the windshield is secured. Note: Spraying the grommets with soapy water may help with installation.
31. Test the lights by starting the snowmobile in a well-ventilated location. The auxiliary lights are off when snowmobile headlights are switched to low beam and on when the headlights are switched to high beam.
For more information, see your authorized Polaris Dealer. To find a dealer near you, use the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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