Hi Guys,

I found these instructions on another site, saved to my pc. I have been out of town and just got back, soory for the delay in responding. The author posted them in '03. Within his original post was the "will not work with EFI" warning so I figured I needed to post it along with the rest of the instructions. There was a post to an explanation of why it would not work (and another kit to use), but that url is no longer valid. Here is the original post verbatim:

3 Headlight Conversion
by jimmypsp700, 2005-08-26


Polaris, 3 Lamp headlight Conversion
June 11 2003
Updated March 05 2004

The relay method will not work on the EFI and therefore you will need to use this (or similair) kit. http://atvfrontier.com/postt3039.html

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. http://www.radioshack.com/prod...product%5Fid=275%2D226
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

Dimensions: .................................... 2 x 1 3/16 x 1 1/8 Inches

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.

 

Cypher,

If this is true with those instructions of making that device WILL NOT work
on EFI, then I recommend those to buy the Quadovator products ($8, I think?).
My cousin has an 2006 800 EFI and we installed it. It works!

R'

 

quadovator.com is the answer.

 

Personally I still like the relay idea better, and I'm still confused as to why it won't work on EFI models because like I've said, I've done 3 of them with no problems

 

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