This video goes over the installation of the Front Roof Light Bar Mounts (part number 2889643) and Front Roof Light Bar Harness (part number 2889892). Installing these kits is necessary before installing any of the following lights:
- Rigid® 32” Combo LED Light Bar (part number 2884299 - shown)
- Pro Armor 31” Dual Row Combo LED Light Bar (part number 2889790)
- Pro Armor 33” Single Row Combo LED Light Bar (part number 2889791)
- Pro Armor 40” Single Row Combo LED Light Bar (part number 2889793)
|Required Tools and Supplies
|5mm Allen Socket
|T25 TORX® Socket
|T30 TORX® Socket
|T40 TORX® Socket
|Drill & 11/16-Inch (17mm) Drill Bit
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when installing accessories on your Polaris XPEDITION.
To install the Front Roof Lightbar Mounting Kit on your Polaris XPEDITION, follow these steps.
1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key.
2. Disconnect the battery with a T40 TORX® socket by removing and keeping the two screws from the front of the driver’s seat base.
3. Lift the front of the seat and pull forward to remove.
4. Use a flathead screwdriver to turn the screw to open the battery cover. Lift and slide it forward to remove.
5. Disconnect the negative cable from the battery with a 13mm wrench.
6. To remove the grill, turn each stud one-quarter turn to release.
7. Pull the top of the grill forward and lift up.
8. Pull the rubber straps off the hooks to release the hood. Lift up to remove.
9. For vehicles equipped with a tip-out windshield, open the windshield and support the weight of the windshield while using the appropriate tool to release the clip at the lower end of the gas spring. Note: Use care when releasing the clip. The clip may spring away from the fitting and may strike objects or become lost.
10. Disconnect the bottom of the gas spring(s) by removing the two screws and ball stud from the lower A-pillar trim panel. Use a flathead screwdriver, T30 TORX® and 11mm wrench.
11. Pull the A-pillar trim piece away from the vehicle and set it aside. Repeat on the other side.
12. Remove the three screws and washers from the windshield base with a T30 TORX®, and set them aside.
13. To remove the panel, start by removing and keeping the two push-pin rivets from the center dash panel with multi-function pliers.
14. Remove and keep the panel by lifting the front edge and moving backward.
15. To remove the head unit, start by removing and keeping the two push-rivets from the top of the head unit.
16. Pull the top of the head unit away from the dash and lift to remove it from the dash.
17. Disconnect the wiring harness and antenna from the head unit. Remove and set aside.
18. To remove the dash cover, start by removing the four dash vent covers. Use a pry tool to remove each vent cover. Tip: Make sure the white clips on the back of the vent covers do not become lost.
19. Remove one screw at each side of the dash cover with a T40 TORX®. Tip: The door will need to be fully open to access and remove these screws. Removal of these screws allows the cover to be pulled open in the next step to remove the push-pin rivet.
20. Remove the A-pillar outer cover to gain better access to the dash push-pin rivet. Repeat on the other side.
21. Carefully pull the plastic cover away from the lower A-pillar area, and remove one push-pin rivet from the side of the dash cover.
22. Remove and keep the screws and washers from the front of the dash cover.
23. Open the glove box and remove the four push-pin rivets from the passenger side of the dash cover.
24. Remove the two push-pin rivets from the driver’s side of the dash cover.
25. If the vehicle is equipped with upper tweeters, make sure to unplug the tweeters when removing the dash cover.
26. Lift up and forward to remove the dash cover. Tip: Lift up on the front center of the dash to disengage the two radio retention tabs.
27. For vehicles with rear speakers, start by disconnecting the wiring harness from the rear speaker.
28. Remove and keep the two screws. Remove the speaker and set it aside. Repeat on the other side.
29. To remove the front roof liner, start by removing and saving the two screws and the rearview mirror assembly with a 5mm Allen socket.
30. Remove and keep the two screws to uninstall the dome light with a T30 TORX® socket.
31. Disconnect the dome light from the wiring harness, keep and set it aside.
32. Remove and save the six screws from the top of the roof liner and four screws from the front of the roof liner.
33. Remove the front roof liner and set it aside.
34. To remove the front roof screws, start by removing and keeping the five screws from the front underside of the roof.
35. Remove and keep the three screws, spacers and washers from each side of the roof.
36. Remove and keep the three weld nuts from each side of the roof underside.
37. Use an object to prop up the corner of the roof.
38. To install the harness, start by routing the harness through the upper grommet. Feed it through the dash and bring it across towards the opening in the lower ROPS on the driver’s side.
39. Attach a wire to the harness and feed into the ROPS, pulling gently towards the opening at the top of the ROPS. Tip: Use caution to avoid damaging the harness connector.
40. Pull the harness through the A-pillar until connectors at the dashboard end of the harness line up. Secure the harness to the frame with push-dart clips. Note: Reference the written instructions for the exact locations.
41. Push harness push-darts into the holes at locations 3 and 11. Insert push-darts clip for relay into hole at position L. Note: Reference the written instructions for the exact locations.
42. Connect the harness to the Polaris Pulse Bar.
43. Remove the switch cover from the appropriate opening in the dash and pull the harness through the opening.
44. Connect the switch to the harness and pull the switch into the opening until it seats with an audible click.
45. Clip the harness to the mounting point behind the head unit in the opening. Note: Reference the written instructions for exact locations.
46. To prepare the roof for the lightbar mounting, start by locating the two dimples on the two eyebrow features on the roof. Drill a hole at each dimple with an 11/16-inch (17mm) drill bit. Note: Be careful to control the drill depth to avoid damage to the vehicle.
47. Locate the drill point for the grommet behind the driver’s side eyebrow feature and drill a pilot hole at this location with an 11/16-inch (17mm) drill bit.
48. The lightbar kit will contain a grommet. Measure the grommet to determine the needed hole size. Tip: Grommet may already be installed on the lightbar wiring harness.
49. Be sure to use the appropriately sized drill or hole saw to expand the grommet pilot hole to the correct size for the grommet.
50. Before assembling brackets, refer to your light bar kit instructions for proper mounting procedures.
51. To assemble the brackets for the 32-inch lightbar, start by assembling the hardware. This includes a bolt, rubber washer and nut for each side of the lightbar.
52. Assemble the bracket with the tubular spacer, washer plate, 3mm spacer and washer. Use an 11mm socket to torque to 18 ft-lbs (24.4 Nm).
53. For vehicles with a tip-out glass windshield, you will have hinges at the upper mounting holes. Lightbar mounts will share the upper mounting holes with the windshield hinges. Note: Reference the written instructions for your specific windshield application.
54. Close the tip-out glass windshield and remove one nut and one screw from the upper hinge mounting with a 13mm socket.
55. Install a carriage screw, tubular spacer, washer plate, 3mm spacer and the bracket. Note: Rotate the washer plate so that the other screw can be removed later. The tubular spacer will pass through the hole drilled in the roof.
56. Install one nut. Do not torque at this time.
57. Remove the other nut from the original mounting hardware as well as the carriage screw from the window.
58. Line up the washer plate with the remaining hole and install a carriage screw, tubular spacer and a 3mm spacer.
59. Install a nut, and torque to 18 ft-lbs (24.4 Nm). Repeat steps for the other side.
60. Push the lightbar wiring harness through the hole, place the grommet around the lightbar harness and install the grommet into the hole. Tip: It may be necessary to slit the grommet to enable the harness connector to fit through the grommet.
61. Zip tie an edge clip to the harness, and attach the harness to the roof.
62. To reinstall the roof, remove any object(s) that were used to prop up the roof. Make sure the roof lays flat on the vehicle.
63. Install three weld nuts on each side of the roof underside. Tip: On 2-passenger vehicles the rear nut on each side will need to be held in place while starting screws in the nut. All other nuts will be held in place by brackets on the ROPS.
64. Install three washers, spacers and screws on each side of the roof. Torque screws to 18 ft-lbs (25 Nm).
65. Install five screws in the underside of the roof. Torque screws to 42 in-lbs (4.7 Nm).
66. To install the front roof liner, begin by installing six screws in the top of the roof liner and four screws in the front of the roof liner. Torque roof liner screws to 27 in-lbs (3 Nm). Torque roof screws to 44 in-lbs (5 Nm). Note: Vehicles that are equipped with a rearview mirror will have a fifth screw at the front of the roof liner. Two-passenger cab vehicles will have three additional screws near the rear of the roof liner.
67. Connect the wiring harness to the dome light and install with two screws. Torque screws to 22 in-lbs (2.5 Nm).
68. Install the rearview mirror assembly and two screws. Torque screws to 31 in-lbs (3.5 Nm).
69. To install the rear speakers, start by connecting the wiring harness to the speaker and then use the kept screws. Torque screws to 44 in-lbs (5 Nm). Tip: The top of the speaker has a shape that engages a space in the ROPS. Make sure the speaker is fully seated in the space before installing screws.
70. Reinstall the dash cover, and connect the tweeter speakers.
71. Install five screws and washers in the top of the dash, and install two push-pin rivets on each side of the dash cover.
72. Install four push-pins rivets on the passenger side of the dash cover, above the glove box.
73. Install the four dash vent covers.
74. Install one push-pin rivet at each side of the dash.
75. Install one screw on each side of the dash, and torque to 26.5 in-lbs (3 Nm).
76. To reinstall the head unit, connect the wiring harness and antenna to the head unit. Put the bottom of the head unit into position, and push the top of head unit into the dash.
77. Install two push-pin rivets into the top of the head unit.
78. To reinstall the center dash panel, insert the rear tabs into the dash and lower it into position.
79. Install two push-pins rivets. If your vehicle is equipped with a tip-out windshield, install the windshield base, three screws and three washers. Torque screws to 89 in-lbs (10 Nm).
80. Attach the outer A-pillar trim piece, and install a push pin rivet.
81. To reinstall the lower A-pillar trim, put the trim in position at the base of the A-pillar.
82. Install two screws, and torque to 22 in-lbs (2.5 Nm).
83. For vehicles equipped with a tip-out windshield, put the lower A-pillar trim in position at the base of the A-pillar and install the ball stud. Torque to 22 in-lbs (2.5 Nm).
84. Return the clip at the bottom of the gas spring to the engaged position and connect.
85. Close the tip-out windshield.
86. To reinstall the hood and grill, start by putting the tabs on the hood through the openings in the under-hood liner. Lower the hood into position.
87. Pull the rubber straps down over the hooks to secure it.
88. Put the tabs on the grill through the openings in the front fascia and push the top of grill into proper position.
89. Push each stud in and turn one-quarter turn clockwise to secure the grill.
90. To reconnect the battery, start by connecting the negative cable to the battery. Push the battery cover rearward and lower it into place.
91. Turn the screw to close the cover.
92. Push rearward to engage the seat and lower the front of the seat into place.
93. Install the two kept screws at the front of the seat base. Torque screws to 13 ft-lbs (18 Nm).
94. Test the lightbar by pressing the top of the lightbar switch. To adjust the lightbar, loosen the mounting screw on each end. Adjust as desired and re-torque the screw to specification. Rigid® Light Bars should be torqued to 16 ft-lbs (22 Nm), and Pro Armor Light Bars should be torqued to 14 ft-lbs (19 Nm).
View the instructions for this kit by searching the Polaris Accessory Installation Instruction Site.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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