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Outlaw 500 2006
Polaris Outlaw 500 2006 Manuals
Manuals and User Guides for Polaris Outlaw 500 2006. We have
1
Polaris Outlaw 500 2006 manual available for free PDF download: Service Manual
Polaris Outlaw 500 2006 Service Manual (202 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 9.24 MB
Table of Contents
General Information Chapter 1 1
4
Table of Contents
4
Chapter 1
5
Engine Designation Number
5
Engine Serial Number Location
5
Model Identification
5
Unit Serial Number (Vin) Location
5
Vehicle Identification
5
Vehicle Information
5
Paint Codes
5
Replacement Keys
5
Standard Torque Specifications
6
Vin Identification
5
Specifications
7
2006-2007 Outlaw 500
8
Special Tools
9
Where Used' Table
9
Special Tool Listing
10
Misc. Numbers / Charts
13
Sae Tap / Drill Sizes
13
Metric Tap / Drill Sizes
13
Coversion Table
14
Glossary of Terms
15
General Information
15
Maintenance Chapter 2 Maintenance 2
16
Maintenance
16
Chapter 2
18
Maintenance Chart Key
18
Periodic Maintenance Chart
18
Periodic Maintenance Overview
18
Pre-Ride Maintenance Interval
19
Recommended Pre-Ride Fluid Level Checks
19
Brakes
20
50 - 100 Hour Maintenance Interval
21
100 - 300 Hour Maintenance Interval
22
Fuel System
22
Maintenance References
23
Lubricants and Service Products
24
Polaris Lubricants, Maintenance and Service Products
24
Fuel System and Air Intake
25
Fuel System
25
Fuel Lines
25
Vent Lines
26
Fuel Valve
26
Carburetor Draining
26
Carburetor Pilot Screw Adjustment
27
Idle Speed Adjustment
27
Throttle Inspection
27
Throttle Cable / Electronic Throttle Control (Etc) Adjustment
28
Choke Adjustment
28
Air Filter and Pre-Filter Service
28
Air Box Drain Tube
29
Crankcase Breather Filter Inspection
29
General Vehicle Inspection and Maintenance
25
Pre-Ride / Daily Inspection
25
Frame, Nuts, Bolts, and Fasteners
25
Engine and Transmission
29
Engine Oil Level Check
29
Engine Oil and Filter Service
30
Oil Pump Priming Procedure
31
Compression Test
31
Exhaust Pipe / Spark Arrestor
31
Engine Mount Locations
32
Liquid Cooling System
32
Cooling System Overview
32
Coolant Strength / Type
33
Cooling System Hoses
33
Radiator
33
Recovery Bottle Coolant Level Inspection
33
Cooling System Pressure Test
34
Radiator Screen Removal
34
Final Drive
34
Clutch Adjustment
34
Reverse Lock-Out Lever Inspection and Cable Adjustment
34
Sprocket Inspection
34
Drive Chain Inspection / Replacement
35
Drive Chain Tension
35
Drive Chain Adjustment
36
Rear Driveshaft Boot Inspection
36
Rear Driveshaft Boot "Pressure Equalizing
37
Electrical and Ignition System
37
Battery Maintenance
37
Battery Inspection / Removal
38
Battery Terminals / Bolts
38
Off Season Storage
38
Engine- To- Frame Ground
38
Charging Procedure
38
Spark Plug Inspection
39
Ignition Timing
39
Steering and Suspension
39
Steering
39
Controls
40
Wheel Alignment
40
Steering Inspection / Tie Rod Ends and Hubs
41
Toe Alignment Adjustment
42
Camber and Caster
42
Suspension Spring Preload Adjustment
42
Rear Shock Compression Adjustment
44
Brake System
44
Brake System Inspection
44
Hose / Fitting Inspection
45
Brake Pad Inspection
45
Brake Testing
45
Wheels and Tires
45
Wheels
45
Wheel, Hub, and Spindle Torque Table
45
Wheel Removal: Front or Rear
45
Tire Pressure
46
Tire Inspection
46
Engine
48
Chapter 3
50
Specifications
50
Torque Specifications
50
Es50Pl Engine Service Data
51
Engine Fastener Torque Patterns
53
General Engine Service
53
Piston Identification
53
Compression Test
53
Coolant Temperature Sensor (Thermistor)
54
Cooling System
54
Radiator Cap / System Pressure Test
54
Cooling System Specifications
54
Accessible Components
55
Engine Removal
55
Engine Installation Notes
56
Crankshaft Straightening
57
Es50Pl Engine Lubrication
57
Oil Pressure Test
57
Oil Pump Priming Procedure
58
Oil Flow - Es50Pl
58
Es50Pl Oil Flow Chart
59
Es50Pl Engine Exploded Views
60
Special Tools
53
Upper Engine Disassembly
61
Disassembly
61
Cam Chain Tensioner Removal
61
Cam Chain Tensioner Inspection and Reassembly
61
Camshaft Removal
62
Automatic Compression Release Inspection
62
Camshaft Inspection
63
Cylinder Head Removal
63
Cylinder and Piston Removal
64
Piston Removal
64
Piston and Rod Inspection
65
Lower Engine Disassembly
66
Crankcase Disassembly and Inspection
66
Starter Drive Gears Removal and Inspection
66
Flywheel / One-Way Starter Clutch Removal and Inspection
66
Crankshaft Nut Removal
67
Clutch Cover / Clutch Removal and Inspection
67
Shifter Component Removal and Inspection
69
Oil Pump Removal and Inspection
70
Crankshaft Drive and Cam Gear Removal
70
Cam Chain / Tensioner Blade Removal
71
Crankcase Separation
71
Crankcase Inspection
72
Crankcase Bearing Inspection / Removal / Installation
72
Transmission and Crankshaft Service
73
Transmission Removal and Inspection
73
Transmission Main Shaft Disassembly / Assembly
73
Transmission Reassembly
74
Crankshaft Removal / Installation
76
Crankshaft Inspection
76
Engine Reassembly
77
Crankcase Reassembly
77
Piston Installation
78
Piston Ring Installation
78
Cylinder Installation
79
Cam Chain Installation
79
Camshaft Timing
79
Primary Drive Gear Installation
80
Outlaw Cam Timing Exploded View
81
Cylinder Head Service
82
Cylinder Head Inspection
82
Cylinder Head Warp
82
Cylinder Head Disassembly
82
Cylinder Head Valve Guide / Valve Seat Inspection
83
Valve Guide Removal / Installation / Ream
83
Valve Seat Reconditioning
84
Valve Inspection
86
Es50Pl Adjusting Pad Selection Matrix
87
Cylinder Head Assembly
88
Cylinder Head Installation
89
Cylinder Service
89
Cylinder Inspection
89
Piston-To-Cylinder Clearance
90
Honing to Deglaze
90
Piston Ring Installed Gap
91
Water Pump Service
91
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
91
Water Pump Mechanical Seal Installation
91
Mechanical Seal Removal and Installation (Engine Assembled)
92
Troubleshooting
93
Engine
93
Spark Plug Fouling
95
Cooling System
95
Fuel System / Carburetion Chapter 4 Fuel System / Carburetion
96
Bsr 42 Carburetor Exploded View
97
Chapter 4
97
Fuel System and Carburetion
97
Fuel Tank Assembly
98
Carburetor Jetting
99
Jetting Guidelines
99
Mikuni Jet Part Numbers
99
Special Tools
99
CV Carburetor System
100
Carburetor Function
100
Vent Systems - CV Carburetor
100
Mikuni CV Carburetor Operation
100
Pilot (Idle and Slow) System
101
Starter System (Choke or Enrichment)
102
Float System
102
Main System
103
Pilot Screw
103
Carburetor Disassembly
104
Carburetor Cleaning
105
Carburetor Inspection
105
Carburetor Assembly
106
Float Height Adjustment
106
Fuel Delivery
107
Needle and Seat Leak Test
107
Fuel Level Test
107
Fuel Pump
108
Fuel Pump Disassembly
108
Fuel Pump Inspection / Assembly
108
Troubleshooting
108
Fuel Starvation / Lean Mixture
108
Rich Mixture
109
Poor Idle / Idle too High
109
Idle too Low
109
Erratic Idle
109
Body / Steering / Suspension Chapter 5 Body / Steering / Suspension
110
Body / Steering / Suspension
110
Chapter 5
112
General Information
112
Special Tools
112
Torque Specifications
112
Body Assembly
113
Exploded View
113
Body Component Removal
114
Seat / Side Panel
114
Front Cab
114
Tank Cover
114
Heel Pocket
115
Rear Cab
115
Steering Assembly Exploded View
116
Ball Joint Service
117
Installation
118
Steering Knuckle
117
Removal
117
Installation
117
Front Hub
119
Exploded View
119
Hub Removal
120
Hub Disassembly
121
Hub Assembly
121
Hub Installation
122
Front Suspension Exploded View
123
Front A-Arm Replacement
124
A-Arm Removal and Inspection
124
A-Arm Installation
124
Rear Suspension Exploded View
125
Rear A-Arm Replacement
126
A-Arm Removal
126
A-Arm Inspection
126
A-Arm Installation
127
Rear Housing
128
Exploded View
128
Housing Removal
129
Housing Disassembly / Service
130
Assembly
132
Installation
133
Rear Bearing Carrier
134
Carrier Removal
134
Carrier Disassembly / Inspection
134
Carrier Assembly
135
Carrier Installation
136
Rear Drive (CV) Joint
137
CV Joint Removal
137
CV Joint Service
137
CV Boot Replacement
138
CV Joint Installation
139
Decals
140
Replacement
140
Front Shock Exploded View
141
Rydefx™ FRONT SHOCK
141
Rear Shock Exploded View
142
Rydefx™ REAR SHOCK (Compression Adjustable)
142
Ryde Fx™ Shock Service
143
Shock Specification Chart
143
Piston Orientation
143
Rydefx™ Shock Rebuild Procedure
144
Brakes Chapter 6 Brakes
150
General Specifications
151
Brake Caliper Exploded Views
152
Chapter 6
152
Front Brake Caliper Assembly
152
Rear Brake Caliper Assembly
152
Brake System Overview
153
Front Brake System - Exploded View
153
Rear Brake System - Exploded View
154
Service Notes
155
Brake Noise Troubleshooting
155
Hydraulic System Operation
156
Brake Fluid Replacement and Bleeding Procedure
157
Master Cylinder
159
Removal
159
Installation
160
Front Caliper Service
161
Caliper Removal and Disassembly
161
Caliper Inspection
162
Caliper Reassembly
163
Caliper Installation
163
Front Brake Pads
164
Pad Removal
164
Pad Assembly
165
Brake Burnishing Procedure
165
Front Brake Disc
166
Disc Inspection
166
Disc Removal / Replacement
166
Rear Caliper Service
167
Caliper Removal
167
Caliper Disassembly
167
Caliper Inspection
168
Caliper Assembly
168
Rear Brake Pad
169
Pad Removal
169
Pad Installation
170
Rear Brake Disc
171
Disc Inspection
171
Disc Removal
172
Disc Replacement
172
Troubleshooting
173
Brakes Squeal
173
Poor Brake Performance
173
Lever Vibration
173
Brakes Lock
173
Electrical Chapter 7 Electrical
174
Chapter 7
175
Electrical Service Notes
175
General Information
175
Special Tools
175
Timing Check Procedure
175
Lighting and Controls
176
Neutral / Reverse Position Indicator Switch Test
176
Headlight Lamp Replacement
176
Headlamp Switch Test
176
Headlight Housing Replacement
176
Headlight Adjustment
177
Taillight / Brakelight Lamp Replacement
177
Brake Light Switch Tests
178
Clutch Switch Test
178
Indicator Lamp Replacement
178
Tether Switch Test (Accessory Option)
179
Electronic Throttle Control (Etc) Switch
179
Etc Operation Test
179
Ignition System
180
Ignition System Troubleshooting
180
Circuit Breakers
180
Cranking Output Tests
180
Flywheel Identification
181
DC / CDI Ignition
181
Ignition System Testing
182
Components of DC / CDI Ignition
183
Cooling System
184
Fan Control Circuit Operation / Testing
184
Coolant Temperature Sensor Test (Hot Light)
184
Fan Control Switch Bypass Test
184
Coolant Fan Control Switch Operation Test
185
Fan Motor Current Draw
185
Charging System
185
Current Draw - Key off
185
Charging System "Break Even" Test
186
Alternator Tests (Charging System)
186
Charging System Testing Flow Chart
187
Battery Service
188
Battery Maintenance
188
Battery Inspection / Removal
188
Battery Terminals / Bolts
189
Battery Testing
189
Ocv - Open Circuit Voltage Test
189
Load Test
189
Off Season Storage
189
Charging Procedure
190
Starting System
190
Starter System Troubleshooting
190
Clutch Switch Test
191
Neutral Start Diode Test
191
Starter Voltage Drop Testing
191
Starter Motor Disassembly
191
Brush Inspection / Replacement
192
Armature Testing
192
Starter Reassembly
193
Starter One-Way Clutch Inspection
193
Starter System Testing Flow Chart
194
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