Replacing Headlight Bulb and Housing

There are two types of headlight assemblies. Earlier models use a 48 volt system and newer models use a 12 volt system. If a converter kit has been installed, you will have a 12 volt lighting system.

Replace 48 Volt Headlight Bulb

MXAL47829-UN-12APR13

1. Remove hood (A), and locate headlight housing in the front frame.

2. 
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   Locate headlight assembly housing (B).

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3. Rotate bulb socket (C) counterclockwise approximately 1/3 turn and remove from headlight housing (B).

4. 
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   Push down top of bulb (D) and rotate counterclockwise to remove from socket.

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5. This is not a standard replacement bulb. If bulb replacement is required, use only a 48 volt bulb. Using a 12 volt replacement bulb could cause a blown vehicle fuse.

   Install new headlight bulb (E) into bulb socket (C).

   • Push down top of bulb and rotate clockwise into locked position.
   
   

6. Install bulb socket (C) into headlight housing (B).

   • Rotate bulb socket clockwise into a locked position.
   
   

7. Test head lamp function.

8. When installing the hood be sure there is clearance all around each headlight housing. Premature failure of headlight bulbs may occur if the hood should make contact with a headlight housing.

   Install hood onto vehicle.

Replace 12 Volt Headlight Bulb

1. This procedure is for vehicles equipped with the 48v to 12v converter kit already installed.

   
   MXAL47832-UN-12APR13

   Remove hood (A), and locate headlight housing in the front frame.

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2. 
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   Locate headlight assembly housing (B).

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3. Rotate bulb socket (C) counterclockwise approximately 1/8 turn and remove from headlight housing (B).

4. 
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   Release tabs (D), and disconnect wire connector (E) from bulb/socket assembly (F). Discard the bulb/socket assembly.

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5. Connect wiring connector to new bulb/socket assembly. Install the assembly into housing and rotate 1/8 turn to lock in place.

6. Test head lamp function.

7. When installing the hood be sure there is clearance all around each headlight housing. Premature failure of headlight bulbs may occur if the hood should make contact with a headlight housing.

   Install hood onto vehicle.

Replace Headlight Housing

1. Remove vehicle hood.

2. 
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   48 volt system shown

   
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   12 volt system shown

   Remove bulb socket:
   • 48 volt system: Rotate bulb socket (A) counterclockwise approximately 1/3 turn and remove from headlight housing (B).
   • 12 volt system: Rotate bulb/socket assembly (C) counterclockwise approximately 1/3 turn and remove from headlight housing (D).
   
   

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3. Remove screws (E) securing headlight housing to the utility vehicle frame.

4. Install replacement headlight housing.

   • Attach housing to utility vehicle frame with screws.
   
   

5. Install bulb socket into headlight housing.

   • Rotate bulb socket clockwise into locked position.
   
   

6. Install hood onto utility vehicle.