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POLARIS OFF-ROAD VEHICLES

HELP CENTER

6/5/2020
RZR Headlight Maintenance

The headlight and taillight lenses of your Polaris RZR will become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles.

When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

Headlight Lamp Replacement For RZR 570
Do not service the headlamps until they've cooled sufficiently.

1. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.

2. Turn the lamp counterclockwise to remove it.

3. Install the new lamp. Make sure the tab on the lamp locates properly in the housing. The bulb is part number 4010253 for RZR 570 models and part number 4012279 for 570 EPS/Premium models.

4. Reinstall the harness assembly into the headlight assembly.

NOTE: If your vehicle is equipped with LED headlamps, if a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. See your Polaris Dealer for a replacement.

If an LED headlamp has moisture or fogging inside, disconnect the wiring harness from the headlamp(s) for a few days to allow the moisture to clear out. Do not operate the vehicle at night or in low light conditions without properly working headlights.

Headlight Replacement for RZR 900, S 900, S 1000
To change the headlight, remove the headlight assembly.

1. Disconnect the wire harness from the headlamp assembly. Be sure to pull on the connector, not on the wiring.

Wire harness

2. Remove the three T25 TORX® headlamp mounting screws (1) and three adjustment preload springs (2).

Mounting screws

3. Carefully lift and remove the headlamp assembly from the bumper.

Headlamp assembly

4. Replace the bulb, which is part number 4012279.

5. Reinstall the headlamp adjustment springs onto the front bumper mounting bosses.

6. Insert the three T25 TORX headlamp mounting screws into the headlamp assembly mounting holes.

7. Maneuver the headlamp assembly into position. Be sure all three headlamp springs (2) and mounting screws (1) are properly aligned with the mounting bosses (3) on the front bumper.

Headlamp assembly

8. Fully tighten all three headlamp screws until the headlamp assembly is fuly seated. Back the headlamp mounting screws off 1/8 inch to 1/4 inch (two to three turns).

9. Connect the headlamp electrical connector to the headlamp assembly.

Headlight Replacement for RZR XP 1000, XP Turbo, XP Turbo S, XP Turbo S Velocity, Pro XP, RS1
If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. See your Polaris Dealer for a replacement. Do not operate your vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility.

Headlight Beam Adjustment For RZR 570

RZR 570 headlight diagram

1. Place the vehicle on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. Place the transmission in PARK.

2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

3. Apply the brakes. Turn the ignition switch to the LIGHTS ON position.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8 inches (20 cm) below the mark placed on the wall in the second step. Include the weight of a rider on the seat while performing this step.

5. If adjustment is necessary, turn the headlight adjustment screw to adjust the beam.

6. Repeat the previous two steps until the beam is properly adjusted.

Headlight Beam Adjustment for RZR 900, S 1000, XP 1000, XP Turbo, Pro XP
The headlight beam can be adjusted slightly upward or downward and to the left or right.

1. Position the vehicle on a level surface. The headlight should be approximately 25 feet (7.6 meters) from a wall.

RZR 900 headlight diagram

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Apply the brakes. Start the engine. Turn the headlights to high beam.

5. Include the weight of a rider on the seat while performing this step. Observe the headlight aim. As a starting point, the most intense part of the headlight beam should be 2 inches (5 cm) below the mark on the wall. Adjust to operator preference.

6. Tighten or loosen the two (Pro XP only) or three headlight screws (1) on the rear of the headlight to adjust the beam upward or downward or to the left or right.

Headlight ScrewsRZR 900 headlight screws

Headlight Beam Adjustment for RS1

R S 1 headlight beam diagram

1. Position the vehicle on a level surface. The headlight should be approximately 25 feet (7.6 m) from a wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

4. Apply the brakes. Start the engine. Turn the headlights to high beam.

5. Include the weight of a rider on the seat while performing this step. Observe the headlight aim. As a starting point, the most intense part of the headlight beam should be 8 inches (20 cm) below the mark on the wall. Adjust to operator preference.

6. Tighten or loosen the three headlight screws (1) on the rear of the headlight to adjust the beam upward or downward or to the left or right.

R S 1 headlight screws

Additional maintenance procedures can be found in your Owner's Manual.
To find replacement parts, including bulbs, consult your vehicle's online parts catalog. For more on using the parts catalog, click here.
To find a Polaris Dealer near you, use the Dealer Locator.

TORX® is a registered trademark of Acument Intellectual Properties, LLC 

Keyword(s) headlight , headlamp , bulb , replace , adjust