Polaris Outlaw 500 Manuals

Manuals and User Guides for Polaris Outlaw 500. We have 1 Polaris Outlaw 500 manual available for free PDF download: Service Manual

Polaris Outlaw 500 Service Manual

Polaris Outlaw 500 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
- 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
- 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
- Transmission and Crankshaft Service
  73
- 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 Service
  89
  - Cylinder Inspection
    89
  - Piston-To-Cylinder Clearance
    90
  - Honing to Deglaze
    90
  - Piston Ring Installed Gap
    91
- Water Pump Service
  91
- 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
- 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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