Engine Installation Notes - Polaris Outlaw 500 Service Manual

Engine Installation Notes

After the engine is installed in the frame, review this checklist
and perform all steps that apply:
General Items
• Torque Rear Engine Lower Mount to 90 ft. lbs.
(122 Nm)
• Torque Front Engine Lower Mount to 27 ft. lbs.
(33 Nm)
• Torque Top Engine Mount to 22 ft. lbs. (30 Nm)
• Install previously removed components using new
gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily
pre–ride inspection checklist (refer to Chapter 2 or the
Owner's Manual).
• Verify clutch and lever freeplay according to
procedures in Chapter 2.
• Adjust chain tension according to procedures in
Chapter 2.
Exhaust
• Replace exhaust gaskets. Seal connections with high
temp silicone sealant if applicable.
• Verify all fasteners are in good condition and torqued
properly.
Bleed Cooling System
NOTE: Refer to Page 3.7 for hose routing. Bleeding
generally is necessary after repairs to purge any air
that may remain in the system during filling.
1. Remove radiator cap and slowly add coolant to the bottom
of filler neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap half-way and gently squeeze coolant
hoses to force any trapped air out of system.
4. Again, remove radiator cap and slowly add coolant to the
bottom of fill neck if required.
5. Start engine and observe coolant level in the radiator. Allow
air to purge and top off as necessary. Reinstall radiator cap
and bring engine to operating temperature. After engine is
cool, check level in reservoir tank and add coolant if
necessary.
NOTE: Should the reservoir tank become empty, it
will be necessary to refill at the radiator and repeat
the bleeding procedure.
Engine Break In Period
The break in period for a Polaris ATV engine is defined as the
first ten hours of operation, or the time it takes to use two full
tanks of gasoline. No single action on your part is as important
as a proper break in period. Careful treatment of a new engine
will result in more efficient performance and longer life for the
engine. Perform the following procedures carefully.
New and rebuilt engines require a break-in oil change at 1 hour
of engine run time.
OIL RECOMMENDATION
Polaris PS-4 All Season synthetic oil is specially
formulated for use with wet-clutch transmissions.
Never substitute or mix oil brands. Serious engine
damage and voiding of warranty can result.
For new or rebuilt engines, do not operate at full
throttle or high speeds for extended periods during the
first three hours of use. Excessive heat can build up
and cause damage to close fitted engine parts.
1. Fill fuel tank with unleaded fuel which has a minimum
pump octane number of 87= (R+ M)/2.
2. Check oil reservoir level indicated on dipstick. Add oil if
necessary.
SAFE
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained idle or
sustained high speed.
5. Perform regular checks on fluid levels, controls and all
important areas on the vehicle.
6. Pull only light loads during initial break in.
7. Change break in oil and filter at 1 hour or 100 miles.
ENGINE
ADD 8 OZ
3.9
3