DIY 3 Headlamp/light conversion

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Thrasher
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DIY 3 Headlamp/light conversion

Postby Thrasher » Thu Jun 10, 2004 4:48 pm

I found this on another board, I don't remeber which, I had these saved into a text file..I take no credit for the information listed.
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#1 3 Lamp Headlight Conversion



Converting your Pod light type Polaris Sportsman so that when the high beam selector is on, the bumper lights are also on. (3 headlamps) and when low beam is selected, only the bumper lights are on.

The nicest thing about this mod is that you do not need to cut any wires or drill any holes.

You will need to purchase a standard 4 pin, 12v relay, 4 pieces of 16 gauge wire about 8" long, 4 female crimp on spade connectors(for connection of wires to relay), 4 wire splice connectors.(they are usually blue and you simply insert the wires and squeeze with pliers, then fold back the protective locking cover)

Open the pod and locate the wiring listed below

Relay terminal #30 connect to Polaris green wire (low beams)
Relay terminal #87 connect to Polaris red wire (10 amp protected circuit at the lighter plug)
Relay terminal #86 connect to Polaris wire yellow wire (high beam)
Relay terminal #85 connect to Polaris brown wire (ground)

Use dielectric grease or liquid tape at all electrical connections to prevent corrosion.

They way this functions, is that when you select high beam, you are powering up the relay to give 12v to the low beam circuit from Polaris's 10amp 12v protected circuit. (No fuse needed) Enjoy.
2003 Polaris Sportsman 600 Twin, w/Warn 2500# winch, k&n filter, handguards, Kimpex Deluxe seat/storage, Kimpex front box, WayBackRacks fuel rack. Mud Lites, Mud chunks, a lil tin can :D

[img]http://www.tampagasprices.com/gb/Tampagasbuddy.gif[/img]

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Postby ash2042 » Thu Jun 10, 2004 6:11 pm

Trasher,
I used a little simpler method which also worked. You need part number 276-1661 from radio shack. It will be a piece of wire with a black cylinder on it. There is a a grey stripe on the black cylinder. The wire on the end with the grey stripe goes to the green wire from the headlight switch while the other end goes to the yellow wire. Very simple yet very cheap. You can fit four bikes for about 5 dollars total. It takes up a little less room in the headlight pod.
04.5 Sportsman 500 HO
Warn 2.5 winch

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Thrasher
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Postby Thrasher » Thu Jun 10, 2004 8:26 pm

this is something i found online for a diy dealie..
mine was a simple jobber, 2 splices and i was done.
2003 Polaris Sportsman 600 Twin, w/Warn 2500# winch, k&n filter, handguards, Kimpex Deluxe seat/storage, Kimpex front box, WayBackRacks fuel rack. Mud Lites, Mud chunks, a lil tin can :D

[img]http://www.tampagasprices.com/gb/Tampagasbuddy.gif[/img]

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Ken
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Postby Ken » Sat Jun 12, 2004 6:13 pm

We have the kit from Mountain Jacks. None of us knew how to do it, till we got the kit.
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Postby MrPolaris » Wed Jun 29, 2005 11:21 pm

Ken/Jack/Terry,
did you guys end up doing this to your quads? I think that I might do this next weekend, just as I like to work on these things. . .
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Postby Ken » Wed Jun 29, 2005 11:28 pm

Yeah Dude....All 3 of us did it. I think the kit from Montana Jacks' is worth it.
The last words spoken before a YouTube video is filmed: "Hold my beer, now watch this..."

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Ken Hower
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http://www.rubicontrail.org/

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Postby MrPolaris » Wed Jun 29, 2005 11:37 pm

http://www.montanajacks.com/index.asp?P ... ProdID=244


so now do I want to spend 19.99, or spend 5.99 at radio shack. ..
Hello

My dogs say hello. . .

Fire Marshall Dusty says, "if you are going to weld your gas tank, make sure it is half full and you have your friend do the welding!!!"

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Ken
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Postby Ken » Thu Jun 30, 2005 8:41 am

Up to you...the kit has all the connectors, instructions and switch...if you use it.


I didn't. I set mine up...so if you go to HIGH...all 3 come on.
The last words spoken before a YouTube video is filmed: "Hold my beer, now watch this..."

Regards,
Ken Hower
RTF Director
http://www.rubicontrail.org/

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Postby Ken's700 » Thu Jul 14, 2005 6:30 pm

Has anyone considered making a remote high beam 3rd light mounted on either the front of the rack extender or other and having a cable or sorts move the light left or right when turning?
I have been just thinking about because the extra light is great but it is blocked way too easy when camping from the quads.

Any thoughts?

Ken
Quads No More :(

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Chadd
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Postby Chadd » Thu Jul 14, 2005 10:25 pm

Right here Ken this light is all you need. I've been using it for 3 years on my Sled. I was a little leary about it at first but it works great.

http://www.helmetlight.com/
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Postby MrPolaris » Fri Jul 15, 2005 12:28 am

I love that little rotating image that they have onthe site there. One of them makes it look like the night becomes day, of course on the other side of the quad you will find a million candle power spot light. . .
Hello

My dogs say hello. . .

Fire Marshall Dusty says, "if you are going to weld your gas tank, make sure it is half full and you have your friend do the welding!!!"


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