my fix for headlight pod bracket flexing

170plus

TY 4 Stroke Junkie
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washburn maine
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Snowmobile
2021 polaris assault 850,18 sidewinder ltx,14 nitro xtx,06 apex rtx,
the faster i go the higher the headlights go so i fixed my headlight pod bracket so it wont flex and the headlights will stay on the ground where i have them pointed,the bracket it actually showing small stress cracks in the corners on the very outside of the front cross piece,i used a piece of 1" wide and 3/8"thick aluminum stock,cut it to length and cut the middle out where the bracket has a drop in it,drilled 4 holes and bolted it together,had to trim the bottom to clear the fuel rail in 2 small spots,i had already cut the tabs off hte back of the air filter cover to make it easier to remove and install so there were no other clearance issues,pod is very solid now,it took me about 2 hrs i'd say and $3.50 in parts,let me know what you think
 

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heres another pic,couldnt figure out how to put both pics on one post ?
 

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Let us know how it works in real life once it is set up. A fix for the headlight in the trees for the newer sleds would be a welcome addition to the site. Can you adjust the head light with this mod?
 
i can tell you this much,just pulling on the windshield in the garage with the light shining on the door, it took a lot of pull to get them to move at all where before the furnace blowing on it would almost change it,there have been a lot of helpfull hints on this site so i figured i'd show this to everyone
 
When you bolt that back down could you not shim one side to get the high beam to shoot lower to the ground.
 
Nice job and looks great. It seems like you have a fix for the dreaded headlight issue...........Yamaha needs to take notice. I would like to leave the air box tabs on and if so do you think your mod would allow me to do so.
 
im pretty sure you really dont have to use as big a piece of stock as i used but the local steel supplier was closing at 12,i got there at 11:55 and i was gonna hold them up so i just grabbed a scrap he had there and away we went,if you left the tabs on i think you would just have to trim the bar in those spots,air box cover is plenty stiff enough that the tabs arent really doing much tho,now if we could get some snow huh
 
if you put the 2 6mm bolts in on the side of the headlight pod it won't move at all my dealer never put them in witch they are easy to miss if you don't know they are suppose to be there i just happened to see the clips on the side of the pod a realized bolt's were suppose to be in there.once i put the bolt's in the pod does not move at all you must have over looked that if you guy's need a pic i will be more than happy to put one up.
 
You may be on to something black700. I never had any issues with my Attak last year.
 
black700 said:
if you put the 2 6mm bolts in on the side of the headlight pod it won't move at all my dealer never put them in witch they are easy to miss if you don't know they are suppose to be there i just happened to see the clips on the side of the pod a realized bolt's were suppose to be in there.once i put the bolt's in the pod does not move at all you must have over looked that if you guy's need a pic i will be more than happy to put one up.

please post a pic, that would be great
 
guy's you can easily look at your sled and see where the bolt's go take your top piece off your sled and the sides look at the side pf the pod at the bottom you will see the black metal cross bar then you will see where the bolt go in.i will tell you this it is a short bolt that goes in there once you find what i'm talking about take you pod off and you will see that it is a short bolt that goes in thee it tighten's up inside the clip it DOES NOT go through the clip. i believe it is a 6 mm bolt and once it's in there the pod does not move at all. but in order to take these little burger's off you have to take the side panel's off i've tried but they are to small and can fall down underneath the motor so taking the side panel's off is a must. if i remember i will post a pic and put up a new topic tommorrow i will do it in the morning so you guy's don't have to wait to see what the hell i'm talking about.
 
i just noticed something look at the second pic right side at the top in the middle of the cross member bar and you can see the hole where the bolt goes in, hell that was easy in roder for you guy's to see it it would easier to take the panel's off your sled you can see it with them on but only when you notice where it is
 
hey black700,good point about the bolts but if you notice on the 2nd pic also that where the 2 bolts go in the side of the bracket the paint is marked where the bolt has been installed on the bracket since new,i guess it would be easy for the dealer to miss these but mine have been there the whole time,ive heard a lot of guys on here say they had no problems and thats good,ive had this problem since new and it probably was getting worse all the time,i ride a lot at night and also run a lot of rrbed and lakes so the high speeds really push the lights up in the air,maybe there is a difference in the rtx and gt(factory low windshield) bracket and the attak(factory higher windshield) although i dont think there is,maybe i just go faster at night than most people,maybe a select few sleds have a bracket from the factory that is missing a little material so its weaker,maybe you havent put on enough miles to weaken the bracket enough to notice a big problem yet,im not sure but whatever the case is this will fix the problem i am having with the pod flexing and it sounds like it might help a few others with the same troubles,like i said b4,when i run my low red shield i have less of a problem,when i put on the taller shield to try to keep warm the wind really tweaks it,the guys with these bolts missing from assembly,i wonder what else your dealer forgot to put on when they put it together
 
170plus do you think part of the flexing is from the bottom of the plastic pod. I'm sure that as wind pressure is applied to the windshield the plastic housing gives as well as the metal bracket. I was thinking of affixing the pod to the bracket as well as adding the support. I would just have to remove the bracket and pod as one unit when working on that section.
 


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