Polaris, 3 Lamp headlight Conversion
The relay method will not work on the EFI

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 connects to Polaris green wire (low beams)
Relay terminal #87 connects to Polaris red wire (10 amp protected circuit at the lighter plug) or any red/white wire
Relay terminal #86 connects to Polaris wire yellow wire (high beam)
Relay terminal #85 connects 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.
Link to standard type 12v DC relay.

Specifications

Contacts: .................................................. .. SPST / N.O.

Rating: .................................................. .. 30A at 12 VDC

Coil Rating: ..................................... 12 VDC, 160 mA, 66 Ohms

Pick up Voltage: ............................................... 7.8 Volts

Drop out Voltage: .............................................. 1.2 Volts

Operating Time: ....................... 10 milliseconds at nominal voltage

Release Time: ......................... 10 milliseconds at nominal voltage

Operating Temperature Range: ............ - 30 to + 85 degrees C at 60% RH



Terminal Connections:

Terminal # 85: ................................................ +12 VDC

Terminal # 86: ......................................... Chassis Ground

Terminal # 87 & # 30: ................................... SPST Contacts

ALL THE RELAYS USE THE SAME TERMINAL NUMBERS SO IT DOES NOT MATTER WHICH BRAND YOU USE, THE TERMINALS WILL REMAIN THE SAME.

 

Do you have any more information an why this mod will not work on 700 EFI models?

 

Hey check out my pics to the left here under my ICON for a step by step installation using the Quadovator
product. Its all done for you about $8 I think all you have to do is open your light POD and match up the
wires and slip thru the plasitc connector and use pliers to complete the crimping that crosses the wires
for you, no splicing, soldering or cutting wires necessary.

Easy to do, only takes a few minutes, you just need to trace, open the lightpod, identify the wires
maybe remove a few tie wraps, then crimp the plastic piece and wire, all in the instructions.
So far so good, no problem, and I enjoy the new functionality - 3 Way Lights!

R'

 

The first thing I did when I got my machine was add a toggle to the POD with a crimp splice to both the high and low beam wires, very simple.

the second was put a toggle on the pod for the reverse overide ( works great for plowing. I used the button for an old motorcycle horn I put in the POD.

 

Please explain why you think the mod won't work on an EFI model?? Cause I've done 3 of them now

 

Yea, not sure with your approach
Cypher if it will or won't work on EFI
but for this small cheap Quadovator
product, it does work on EFI.

Also it works for the Sportsman 450-800
models for the last several year models.
The wiring in the POD for at least the light
system and the Reverse Override is all
compatible with the product, again not sure
with your application.

See what you started Scrammy, LOL just joking!

R'

 

the wiring shouldnt be any differnt for efi vs carb when it comes to the lights.

 

This kit sold on ebay works on the 800 EFi, It fits all Polaris sportsman's and takes 5 minutes to install, no cutting of factory wires. Item cost $5.99 And worked great on my atv.

http://stores.ebay.com/Mountai...subZ245007018QQfrsrcZ1

 

Noticed the link for the above didn't work managed to find the same seller for the Polaris 3-way light mod they are offering a single wire kit (2 wire tap install) as well as a relay style kit requires 4 wire taps. Anyone know the difference in reliability or difference between the two kits and have a recommendation? I see they fit all sportsman's with 3 headlights as well as explorer I have a 800 EFI wanted to make sure it would work based on the info above some people said they relay does not work on the EFI.

Ebay Seller
https://www.ebay.com/str/mountainmod...ecat=245007018

Relay Style
https://www.ebay.com/itm/Polaris-Spo...oAAOSwjbpblHE6

Non relay style
https://www.ebay.com/itm/Polaris-Spo...4AAMXQ9qpRSes6

 

I've had 3-headlight mods on several Sportsman 500s. All but the one I have now. None have had relays, but they came with a switch in case you wanted to use the high beam alone. The switches always fail when they get full of dust, etc. The directions from Montana Jack's Outpost covered both ways. Other than the switches they all worked perfectly. When I got tired of screwing around with the switch on the next to last one, I left the switch installed in the hole I made in the pod, and spliced the wires together to bypass it. That's why I installed the last kit without the switch. I would swear the kits I bought were $20, but they're only $4.98 now. I didn't check how much shipping is. The Mountain Mods kits cost half as much at their website as on ebay. Quadovator kits are $12 plus shipping. With no hesitation or reservations, I would get a Montana Jack's kit and install it without the switch.

https://www.montanajacks.com/collect...ts/mtj-phk-100

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https://www.quadovator.com/3_headlight_mod.html