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I'm in the process of moving to my new domain http://www.hillbillydeluxepowersports.com
2005+ Polaris Sportsman Automatic Reverse Lights This guide was written to show you how to install two relays which will automatically turn on your worklights any time you shift into reverse. Your worklight switch will still function as it always has, allowing you to turn on your worklights whenever you wish. Step 1: You will need to first gather the necessary parts to complete this mod. You will need two single pole - double throw (SPDT) 12 volt 30 or 40 amp relays and two relay sockets. I choose to use the 5 pin relays, because that's all I could find. The 4 pin relays will work just fine too and will actually require one less step. I purchased my relays and socket connectors from a company called MCM Electronics. Links to the products can be found here: Relays: http://www.mcmelectronics.com/product/26-534 Relay Datasheet: http://www.mcmelectronics.com/ Sockets: http://www.mcmelectronics.com/ You will also need your choice of splicing parts (butt connectors, wire taps, solder...), electrical tape, shrink tube, wire cutters and strippers and about 10-12 feet of wire. (It may be helpful to have 5-6 feet or two different colored wire). I highly suggest using shrink tube everywhere possible!! Once you have your materials gathered start by plugging in your socket connectors to the relays. We will be using this diagram to help make our connections. I will refer to the relays as Relay #1 (on the left) and Relay #2 (on the right). Step Two: If you chose the 5 pin relays and sockets, you need to first block off the middle pin on each socket. (The red wire) I just cut the wire down to about 1.5 - 2" long and put some heat shrink over the wire. You can tape it up, or use a wire nut, or whatever. I also chose to go ahead and tape my two relays together using electrical tape. Step Three: 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 Four: All of connections except two will be made inside the pod, so the wires that some with the socket connectors will be plenty long enough. However, we need to lengthen two of the wires to reach the plug on the transmission. First, locate the transmission plug on the right side of the machine.
Cut the zip tie(s) holding on the plastic sheath around the wires going to the plug. Identify the PURPLE wire inside the sheath and cut it about 3 to 6 inches from the plug. You will need to fish two wires from the pod/relays to this switch. If you're using the same color wire for both, you WILL need some way of keeping the two wires identified separatly though. It WILL matter which one gets plugged where. Once your wires are ran down to the switch, you will need to splice them into the relays. Splice the two pin 86 wires together (the white wires in the pictures), then connect those two wires to one of the wires running to the transmission switch (the black wire in the picture) Splice the other wire (the red wire in the picture) to pin 87 on relay #1 (the yellow wire). Step Five: Now we can start making our connections at the transmission plug. Connect the wire coming from the two 86 pins to the piece of the purple wire going INTO the plug. Connect the other wire we ran (the one comin from pin 87 on relay #1) to the piece of purple wire going AWAY from the plug. ***Sorry, but I didn't think to get a picture of these connections*** Step Six: Using your connection method of choice (I globbed on the solder) you need to connect the two wires from the 85 pins and the 30 pin of relay #2 with a fourth wire that's a about 4-6 inches long. Connect that forth wire you spliced into the three relay wires to the red and white striped wire going to your worklight switch. Step Seven: Again, using your method of choice, make the following connections: Pin 87 of relay #2 to the BLUE wire going to your worklight switch. Pin 30 of relay #1 to the BROWN wire going to your accessory plug. Step Eight: PLUG YOUR SPEEDOMETER AND WORKLIGHT SWITCH BACK IN (I forgot that when first testing mine) and test your work. Your worklights should function as they always have by using the switch, no matter what gear you're in. With the switch OFF, when you shift into REVERSE your worklight should automatically turn on. Shifting out of reverse should make the lights go back off. 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.
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