This video goes over the installation of the 50" Light Bar Harness (part number 2889591) and RIGID® RDS SR-Series 50" Curved Single-Row Light Bar (part number 2889567).
Required Tools and Supplies
- T25 TORX®
- T30 TORX®
- T40 TORX®
- Multi-Function Pliers
- Drill and 1/8-Inch Drill Bit
- 1 3/8-Inch Hole Saw
- Ratchet
- 10mm Socket
- 11mm Socket
- 13mm Wrench
- Pry Tool
- Torque Wrench
- Fish Wire
- Flathead Screwdriver
- Shop Rags
- Nitrile Gloves
- Eye Protection
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 50” Lightbar 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. Use a T40 TORX® socket to disconnect the battery by removing and retaining the two screws from the front of the driver’s seat base.
3. Slide the front seat and lift up to remove.
4. Turn the screw to open the cover. Lift the cover and slide forward to remove.
5. Disconnect the negative cable from the battery with a 13mm wrench, to prevent arcing.
6. If equipped with accessory hood rack, remove it and set aside.
7. To remove the grill, turn each stud one-quarter turn to release.
8. Pull the top of the grill forward and then lift up to remove the grill.
9. Pull the rubber straps off the hooks to release the hood. Remove the hood by lifting the hood up.
10. Open the left front door.
11. For vehicles equipped with the 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. Caution: Use care when releasing the clip. The clip may spring away from the fitting and may strike objects or become lost.
12. With a T30 TORX® and 11mm socket, disconnect the bottom of the gas springs and remove the two screws and ball stud from the lower A-pillar trim panel.
13. Pull the A-pillar trim piece away from the vehicle.
14. Remove the outside A pillar trim or side mirror, if equipped, by removing the push pin rivet and pulling away from the vehicle. Repeat on the other side.
15. The panel removal process starts by removing and retaining the two push-pin rivets from the center dash panel with multi-function pliers.
16. Remove and keep the panel by lifting the front edge and moving backward.
17. To remove the head unit, remove and retain the two push-pin rivets from the top of the head unit. Note: For vehicles without an audio system, there is a storage bin in place of the head unit. The storage bin is removed in a similar manner to the head unit.
18. Pull the top of the head unit away from the dash, and lift the head unit up to remove from the dash.
19. Disconnect the wiring harness and antenna from the head unit. Remove and set aside.
20. To remove the dash cover, start by removing the four dash vents covers by using a pry tool. Pry at the top and bottom cover to remove. Note: Make sure the white clips on the back of the vent covers do not become lost.
21. Remove one screw at each side of the dash cover with a T40 TORX®. Tip: Doors 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.
22. 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.
23. Open the glove box, and remove the four push pin rivets from the passenger side of the dash cover with multi-function pliers.
24. Remove two push pin rivets from the driver’s side.
25. Remove and retain the five screws at the front of the dash cover with a T25 TORX®. Tip: Lift up on the front center of the dash to disengage the two radio retention tabs. Note: If your vehicle is equipped with upper tweeters, make sure to unplug the tweeters when removing the dash cover.
26. To remove the front roof liner, use a 5mm Allen socket to start by removing and retaining the two screws and rearview mirror assembly (if equipped).
27. Remove and retain the two screws to uninstall the dome light with a T30 TORX® socket.
28. Disconnect the dome light from the wiring harness and remove. Set the dome light aside.
29. Remove and retain the six screws from the top of the roof liner and the four screws from the front roof liner with a T30 TORX® and T40 TORX®. Note: Vehicles that are not equipped with rearview mirror will have a fifth screw at the front of the roof liner. Vehicles equipped with a 2-passenger cab will have three additional screws near the front of the roof liner.
30. Remove and retain the front roof liner.
31. Remove and retain the two screws and set the speaker aside.
32. Remove the rear speakers by disconnecting the wiring harness with a T40 TORX®. Repeat on the other side.
33. Remove the nine screws from the middle roof liner with a T30 TORX®, and set aside.
34. To remove the front roof screws, start by removing and retaining the five screws from the underside of the roof.
35. Remove and retain all of the screws, spacers and washers from each side of the roof with a 13mm wrench. Note: For better access, remove rack platform from the vehicle.
36. Remove and retain the three weld nuts from each side of the roof underside.
37. Use an appropriate tool to prop up the roof.
38. Carefully remove the side cover near the opening at the ROPS bottom.
39. 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.
40. To install the harness and switch, begin by locating the opening in the ROPS at the base of the left A-pillar tube.
41. 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. If the vehicle is equipped with a poly windshield, remove the upper windshield mounting hardware to avoid interference between the harness and screw, inside the A-pillar tube.
42. Feed the wiring harness through the ROPS A-pillar while watching for the end to appear in the opening above the driver’s side window area and pull through the opening in the ROPS. Tip: A pick or hook can be used to help pull the end of the harness through the opening.
43. Pull the harness through the A-pillar until the connectors at the dashboard end of the harness line up with the frame.
44. Secure the harness to the frame with the push-darts. Note: Reference written instructions for exact locations.
45. Push the harness push-darts into holes at locations 3 and 11. Install the push-dart for the relay into the hole at position L.
46. Connect the harness to the Polaris Pulse bar.
47. Remove the switch cover from the appropriate opening in the dash, and pull the harness through the opening.
48. Connect the switch to the harness, and push the switch into the opening until it seats with an audible click.
49. Clip the harness to the mounting point behind the head unit opening. Note: Reference the written instructions for exact locations.
50. To prepare the roof for the lightbar mounting, locate the two dimples on each front corner of the roof. Drill a 1/4-inch hole in both dimples. Note: To avoid injury, ensure the rack is secure or removed completely from the roof.
51. Locate the drill point for the grommet behind the driver’s side eyebrow feature and drill a 1/8th inch hole.
52. Measure the grommet to determine the size hole you need to fill. Tip: The grommet may already be installed on the light bar wiring harness.
53. Use the appropriately sized drill or hole saw to expand the grommet pilot hole to the correct size for the grommet.
54. To assemble the lightbar mounts, begin by installing screw heads in sockets in the end of the lightbar. Assemble the bracket over the screw heads. Repeat on the other side. Note: The bracket will click into the end of the lightbar.
55. Assemble the mount, two washers and two nuts to the end of the lightbar with an 11mm socket. Do not torque at this time.
56. Install the T-washer that was previously removed from the front roof screw holes. Install the T-nut underneath the roof. Repeat on the other side.
57. Position the lightbar on the roof, and install the bolt on the lightbar bracket. Tip: If the vehicle is equipped with the platform roof rack, do not use the provided washer.
58. Install two screws in the front mounting holes with a 10mm socket.
59. Install washers and nuts on the front screws. Torque to 80 in-lbs (9 Nm).
60. Remove any object propping up the roof. Make sure the roof is lying flat.
61. Fasten the screw into the roof with a 13mm socket and 13mm Crow’s Foot. If you have a Rhino-Rack®, torque to 88 in-lbs (10 Nm), and torque to 212 in-lbs (24 Nm) if you don't.
62. 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 opening.
63. Connect the lightbar harness to the vehicle harness.
64. Clip the edge clip to the vehicle roof.
65. Install five screws in the underside of the roof. Torque to 42 in-lbs (4.7 Nm).
66. Reconnect the windshield wiper motor, if equipped.
67. To install the rear roof liner, begin by installing the nine retained screws.
68. Connect the wiring harness to the speaker.
69. To install your rear speakers, begin by using the two retained screws. Torque to 44in-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 this space before installing the screws.
70. 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 top screws to 27 in-lbs (3 Nm), and torque front screws to 44 in-lbs (5 Nm).
71. Connect the wiring harness to the dome light.
72. Install the dome light and two screws. Torque to 22 in-lbs (2.5 Nm).
73. Install the rearview mirror assembly and two screws. Torque to 31 in-lbs (3.5 Nm).
74. To install your dash cover, place the front of the dash cover in position and set into place.
75. Connect the speaker wires if necessary. Make sure the center of the dash is placed in slots on the vehicle. Tip: If the head unit/storage bin was not removed, make sure these tabs are inserted behind the head unit trim.
76. Reinstall lower front A-pillar cover.
77. Install five fasteners on the top of the dash.
78. Install two push pin rivets on the driver’s side of the dash cover.
79. Install four push pin rivets on the passenger side of the dash cover.
80. Install the four dash vent covers. Push them evenly at the top and bottom to install.
81. Install one push pin rivet on each side of the dash.
82. Install one screw at each side of the dash. Torque to 26.5 in-lbs (3 Nm).
83. To install the head unit, begin by connecting the wiring harness and antenna to the head unit.
84. Put the bottom of the head unit into position by pushing the top of the head unit into the dash.
85. Install two push-pin rivets into the top of the head unit.
86. To install the center dash panel, begin by inserting the rear tabs into the dash and then lowering it into position.
87. Install two push-pin rivets. Note: If the vehicle is equipped with a tip-out windshield, install the base with the three screws and washers. Torque to 89 in-lbs (10 Nm).
88. To install the lower A-pillar trim, begin by putting the lower A-pillar trim in position at the base of the A-pillar.
89. Install three screws. Torque to 42 in-lbs (4.7 Nm) if you have side mirrors, and torque to 22 in-lbs (2.5 Nm) if you do not.
90. For vehicles with a tip-out windshield, put the lower A-pillar trim in position at the base of the A-pillar.
91. Install two screws and a ball stud. Torque to 22 in-lbs (2.5 Nm).
92. Return the clip at the bottom of the gas spring to the engaged position, and connect the bottom of the gas spring.
93. Remove any windshield support, and close the tip-out windshield.
94. To install the hood, begin by putting the tabs on hood through the openings in the underhood liner. Lower the hood into position.
95. Pull the rubber straps down over the hooks to secure the hood.
96. Put the tabs on the grill through the openings in the front fascia, and push the top of the grill into proper position.
97. Push each stud in and turn one-quarter turn clockwise to secure the grill.
98. Reinstall the hood rack, if equipped, by engaging the four latches.
99. Reconnect the negative battery cable to the battery.
100. Push the battery cover rearward and lower it into place and turn the screw to close the cover.
101. Put the seat in place and push rearward to engage the seat. Lower the front of the seat into place, and install the two retained screws at the front of the seat base. Torque to 13 ft-lbs (18 Nm).
102. Test the lightbar by pressing the switch on top of the lightbar switch. Loosening the mounting screws on each end of the lightbar will help with adjusting its position. Torque to 16 ft-lbs (22 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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© 2023 Polaris Industries Inc.
