Quantcast
Jump to content

  • Join Today, It's Simple and FREE!

    As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery.  Registration is fast and you can even login with social network accounts to sync your profiles and content.

AZRocks

Tail Lights Off Mod - Polaris Sportsman 500

Recommended Posts

This is a 2008 Polaris Sportsman 500 X2 modification to make the taillights only come on when the headlights are on. Normally the taillights are always on, which I admit is very helpful when following someone on the trail in lowlight conditions. I prefer to have the option of when the lights are on, so I installed the following mod to my Polaris.

Parts:

- 1 x Bosch style relay. Amazon: AGT (5 Pack) 30/40 AMP Relay with Harness; spdt 12V Bosch Style (40AMP-HRNS) for 13.99.

- 1 x 1N400X diode (I used a 1N4004, but any diode in the series should be fine)

- Wire connectors, preferably marine grade heat shrinkable.

- Heat shrink wrap.

- Wire protection: split loom and nylon sleeve.

- Wire: 5 feet of 16-18 gauge.

Bosch relay info: CHETS CIRCUITS (and scroll down to yellow diagram near mid page--thanks Chet)

Basic concept:

1. Splice into a headlamp wire and run it to relay pin 85; ground pin 86 to the frame.

2. Cut the two taillight wires (L and R), and connect one side of the cut (both L and R) to relay pin 30, and the other side to pin 87.

3. When the headlights are on, power from the headlight wire to pin 85 causes the relay to close the taillight connection through pins 30 and 87 to make the taillights turn on. When the headlights are off, the connection between pins 30 and 87 is open, resulting in the taillights being off.

4. The brake lights are on their own circuit, so will still work normally.

5. The relay only draws about 170 milliamps from the headlight splice so there is no apparent change in headlight intensity.

6. I don’t think joining the individual L and R taillight wires to pass through the relay (pins 30 and 87) has any effect on the electrical system since they come from the same splice upstream.

My install used a 5 pin relay with pig tail wire connector. I removed the unneeded center pin wire (87a pin):

[ATTACH]1759[/ATTACH]

I pulled out the 85 and 86 wire pins and soldered a 1N4004 diode in as a precaution against back EMF. Back EMF is a voltage spike caused when power is removed from the relay that could cause damage to switches in a system not specifically designed to have a relay. An electrician may know better whether or not this is needed to protect the headlight system of the quad. Note the diode’s cathode end must connect to the power wire (pin 85 in this case), and anode end must connect to the grounded wire (pin 86), I.E. Reversing the diode polarity will cause a short and potential damage. An option is to purchase a relay with an integrated diode. Diodes are cheap at Radio Shack. I suspect installing a diode is overkill, but I had the time and energy . . .

Soldered in diode and with connectors and diode reinstalled:

[ATTACH]1764[/ATTACH]

Next, I found a place to mount the relay. On the left side frame, next to the air box, was a foot-well brace bar that bolts into the frame. I mounted the relay on this bolt and also connected the relay ground wire (pin 86) to the bolt by crimping a ring connector to the wire:

[ATTACH]1762[/ATTACH]

Then I very carefully removed a half inch of insulation from the front left headlight power wire (a green wire on my quad) and soldered in a wire to connect to pin 85. I put a nylon sleeve on this wire and ran it back to the relay, following existing wire looms and zip tying it in place:

[ATTACH]1763[/ATTACH]

Next I accessed the taillight wires--the PS500 X2 made this easy since it has a dump bed that lifts up. For typical quads, you may need to remove the rear storage rack to access the taillight loom. As you can see in the pic, my taillight wires are red w/white trace, the brake light wires are orange, and the ground wires are dark brown. Cut the taillight wires and crimp on connectors, then connect to pins 30 and 87 (black and blue wires in my case). Polarity doesn’t matter. View from above:

[ATTACH]1763[/ATTACH]

Made all the connections to the relay then tested the light system. Worked like a champ. I used shrink wrap and tape to seal the connections then put split loom wire protection over the wires between the relay and taillight loom and zip tied everything in place.

I also spliced in a license plate light to the taillight circuit. I used tape to mask the dome so only a slit is open to shine softly on the plate.

Had a couple more pics, but apparently can only upload up to 5 total, or per post.

57d7734a2a3b2_PS500X2TailLightsMod-1.jpg.c9731e81720b3134315b98ccc748060a.jpg

57d7734a2d681_PS500X2TailLightsMod-4.jpg.192396448300c7c14eb5f38215d5d848.jpg

57d7734a2f9a2_PS500X2TailLightsMod-5.jpg.238113dd5985e710a432246ad6d71b37.jpg

57d7734a320dd_PS500X2TailLightsMod-23.jpg.256a8c740d17b2e5563fbb74300c0b26.jpg

Share this post


Link to post
Share on other sites


Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

  • Similar Forum Topics

    • Michigan guy looking for (over 50) ATV friend to camp/trail ride with

      Summer days here in the northern part of the state don't last that long! Right now is perfect riding conditions with cooler nights slowly creeping in. 
        My son and I will be going up this weekend but its been nearly 2 months since our last trip up and after our next trip it could be quite some time before he'll be able to get more time off work. 
        If you know anyone that might like a few days out up north to do a trip to ride and camp please get in touch real soon! Thanks Steve

      By 4tracker, in Midwest ATV & Off Road Forum

        
      • 4 replies
      • 196 views
    • Polaris Online Parts Catalog

      Here is the Polaris online parts catalog, looks like you need to register with then first. I haven't used it since I'm not a Polaris owner and don't need any parts right now... http://parts.polarisind.com/Browse/Browse.asp

      By Ajmboy, in Polaris ATV Forum

        
      • 7 replies
      • 7,116 views
    • Polaris ATV Valve Adjustment

      I've never done this before but after reading a few thread I decided to check my valves for the first time and to my surprise it was much easier than I thought. My bike is a 2005 Sp 500 HO. I first pulled the seat and the right side panel off, and that's it! It wasn't too bad to get at. Next I pulled the spark plug out and removed both the head cover ( 8-8mm bolts) [ATTACH]1021[/ATTACH] then the side cam cover (5-8mm bolts). [ATTACH]1023[/ATTACH] Also remove the plug in the recoil cover (14mm bolt) to see the timming marks. [ATTACH]1022[/ATTACH] Next I turned the engine over with the pull cord untill it was at TDC of the compression stroke. The best was to tell that your at TDC of the compression stroke is to rotate the engine until the timing marks are parallel to rocker cover gasket surface. The cam sprocket locating pin will be facing upward directly in line with the crankshaft to camshaft center line. Now fine adjust by looking into the timing hole in the recoil cover and line up the upside down "T" on the flywheel into the center of the hole. [ATTACH]1023[/ATTACH] Now using a feeler gauge, slide the .006" (.15mm)blade between the top of the valve and the bottom of the adjuster and adjust accordingly [ATTACH]1024[/ATTACH] [ATTACH]1025[/ATTACH] To adjust, Loosen the locknut (10mm) and check clearance with a feeler guage. Clearance should be .006" (.15mm) for both, intake and exhaust valves. Turn the adjuster with a stubby flat blade screwdriver untill the proper clearance is achieved then tighten the locknut (5.8-7.2 ft. lbs) while holding the adjuster in place with the screwdriver. Re-check the clearance with the feeler guage one last time and re-assemble the covers (72 in.lbs) and plugs. The only thing that i noticed was that I had to clean and silicone the side cam cover other than that I found the whole process rather simple. I'd give it a 4 out of 10 on the skill level scale. I hope this helps! Thanks Rich

      By PolarisRich, in Polaris ATV Forum

        
      • 7 replies
      • 23,362 views
    • 1996 Polaris Sportsman 500

      I am new here and just wanted to say Hi. I just acquired a 1996 Sportsman 500 that a family member bought new and used for a week each year at a hunting camp. It was always stored inside and serviced regularly. If anyone is aware of anything on this machine that needs special attention I welcome your advice. Thanks

      By lagomu, in Polaris ATV Forum

      • 3 replies
      • 119 views
    • STOLEN ATV: Stole 2016 Polaris Rzr XP 1000

      We just bought a new home. It needed severa things done and we have had several people to our home for repairs. Not sure if it was any of those. Less the one month at new home and the ATV was stolen from our driveway. There were NO keys in it. We have a long driveway and you can see where they had dragged it to the road. Police report made same day. The post Stole 2016 Polaris Rzr XP 1000 appeared first on Stolen 911. View the full article

      By StolenATV, in Stolen ATVs

      • 0 replies
      • 37 views
  • Similar Tagged Content

  • Recently Browsing   0 members

    No registered users viewing this page.


×