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POLARIS COMMERCIAL
HELP CENTER
11/10/2021

Pro XD Headlight Adjustment and Replacement

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.
 
Note: When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
 
To order replacement headlight bulbs, contact your authorized Commercial Dealer
 
Headlight Bulb Replacement
 
1. Remove the hood from the front cab.

2. Locate the bulb on the back side of the headlight housing.

3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring.
headlight connector

4. Turn the bulb counterclockwise and remove it from the headlight housing.
headlight bulb
5. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place. Make sure the tab on the bulb locates properly in the housing.
 
6. Install the harness onto the new headlight bulb and install the hood.
 
Headlight Beam Adjustment
 
Pro XD headlight adjustment
 
To adjust the headlight beam, do the following:

1. Place the vehicle on a level surface with the headlight approximately 25 ft (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Apply the brakes. Start the engine. Turn on the headlights.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8 in (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat while performing this step.
 
5. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.
 
6. Loosen the screw, adjust the headlight, and tighten the screw.
 
7. Repeat steps 4-6 until the lamp is properly adjusted.
 
Brake Lights
When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.
 
To check the brake lights, do the following:
 
1. Turn the key to the ON position.
 
2. Depress the brake pedal. The brake light should come on after about 0.4 in (10 mm) of pedal travel. If the light doesn't come on, check the bulb.
 
To purchase replacement parts and fluid, or for maintenance assistance, contact your Commercial dealer. To find a dealer near you, use the Dealer Locator
For more maintenance procedure information, refer to your Owner's Manual
For information on tools, read the Tools and Fasteners Guide.
Keyword(s) head , light , brake , adjust , new , bulb , replace , beam , screw ,