2005+ Polaris Sportsman 3 Headlight Mod

This guide will show you how to do yet another easy electrical modification that Polaris should have made standard from the factory.  This mod will allow your low beam headlights to function just as they always have; however, your high beams will be significantly brighter.  This mod will allow you to run your low beam lights along with your pod-mounted high beam when you switch on your high beam.  This is a common mod people have been performing on a number of vehicles for years.

Step One:

You will need to either build or purchase the diode kit to that splices in between your high and low beam wiring.  Like many people, I choose to spend the extra couple of dollars and purchase a kit off eBay.  The kit I purchased was less than $5 including shipping.  By the time you buy the diode, wiring, shrink tube, and connectors...you could of just bought the $5 kit from eBay. 

I have recently obtained the information to build your own "kit."  I personally have not verified this information, but I'm sure it's good info.

You will need a 6 amp, 50V rectifier/diode (Radio Shack part number 276-1661)

Splice some wire onto each end of the diode.  (It will help greatly if you use two different colors of wire.)  My eBay bought kit used red and black.  Use heat shrink tubing to seal the ends of the diode, as shown below.  The end of the diode with the silver stripe will go to the green wire in your headlight wiring and the black end of the diode will go to the yellow wire of your headlight wiring.  You ultimately want your current to "flow" from green to yellow

Here's what the kit comes with...

Step Two:

Remove the three phillips head screws holding the headlight pod on.

Once the pod is free, unhook the two wiring harnesses plugged into your speedometer and your worklight switch (if equipped) and set the pod aside.

Step Three:

Locate the wiring bundle coming from your headlight switch and follow it down into the pod.  Cut a 1 1/2 to 2 inch slit in the rubber sheathing.  Be careful not to cut any of the wires inside.

Step 4:

Locate the yellow wire in the bundle and using the tap connector in the kit, splice the red wire from the diode to it.  (You can also solder this connection.)

Step 5:

Repeat step 4 splicing the black wire from the diode to the green wire in the wiring bundle. (You can also solder this connection.)

Step 6:

You can now test your connections by seeing if everything works properly.  If everything is working properly you should see this only when your high beams are on:

Step 7:

Once you have confirmed everything is working, you need to tape up your connections with electrical tape.  Note: It is important NOT to wrap the diode in tape.  I have heard of people experiencing the diodes getting pretty hot.  You want to leave the diode out so that in can get air flow around it.

Step 8:

Being careful not to pinch anywires, reconnect your speedometer harnesses and screw your pod back on.

Disclaimer

I will not be held responsible should you damage something on your ATV while performing this modification or as the result of this modification.  This page was written simply as a guide, to help you complete the modification and to show you what to look for while performing the modification.  You should only attempt this modification if  you are mechanically inclined enough to do so.