Name: Polaris Outlaw 500 Service Manual
Brand: Polaris
Rating: 5 (1 reviews)

4. Table of Contents
5. VEHICLE IDENTIFICATION
6. STANDARD TORQUE SPECIFICATIONS
7. SPECIFICATIONS
8. 2006-2007 OUTLAW 500
9. SPECIAL TOOLS
10. SPECIAL TOOL LISTING
13. MISC. NUMBERS / CHARTS
14. COVERSION TABLE
15. GLOSSARY OF TERMS
16. MAINTENANCE
18. PERIODIC MAINTENANCE CHART
19. PRE-RIDE MAINTENANCE INTERVAL
20. BRAKES
21. 50 - 100 Hour Maintenance Interval
22. 100 - 300 Hour Maintenance Interval
23. MAINTENANCE REFERENCES
24. LUBRICANTS AND SERVICE PRODUCTS
25. GENERAL VEHICLE INSPECTION AND MAINTENAN...
26. VENT LINES
27. CARBURETOR PILOT SCREW ADJUSTMENT
28. THROTTLE CABLE / ELECTRONIC THROTTLE CON...
29. AIR BOX DRAIN TUBE
30. ENGINE OIL AND FILTER SERVICE
31. OIL PUMP PRIMING PROCEDURE
32. ENGINE MOUNT LOCATIONS
33. COOLANT STRENGTH / TYPE
34. COOLING SYSTEM PRESSURE TEST
35. DRIVE CHAIN INSPECTION / REPLACEMENT
36. DRIVE CHAIN ADJUSTMENT
37. REAR DRIVESHAFT BOOT "PRESSURE EQUALIZIN...
38. BATTERY INSPECTION / REMOVAL
39. SPARK PLUG INSPECTION
40. CONTROLS
41. STEERING INSPECTION / TIE ROD ENDS AND H...
42. TOE ALIGNMENT ADJUSTMENT
44. REAR SHOCK COMPRESSION ADJUSTMENT
45. HOSE / FITTING INSPECTION
46. TIRE PRESSURE
50. SPECIFICATIONS
51. ES50PL ENGINE SERVICE DATA
53. SPECIAL TOOLS
54. COOLANT TEMPERATURE SENSOR (THERMISTOR)
55. ACCESSIBLE COMPONENTS
56. ENGINE INSTALLATION NOTES
57. CRANKSHAFT STRAIGHTENING
58. OIL PUMP PRIMING PROCEDURE
59. ES50PL OIL FLOW CHART
60. ES50PL ENGINE EXPLODED VIEWS
61. UPPER ENGINE DISASSEMBLY
62. CAMSHAFT REMOVAL
63. CAMSHAFT INSPECTION
64. CYLINDER AND PISTON REMOVAL
65. PISTON AND ROD INSPECTION
66. LOWER ENGINE DISASSEMBLY
67. CRANKSHAFT NUT REMOVAL
69. SHIFTER COMPONENT REMOVAL AND INSPECTION
70. OIL PUMP REMOVAL AND INSPECTION
71. CAM CHAIN / TENSIONER BLADE REMOVAL
72. CRANKCASE INSPECTION
73. TRANSMISSION AND CRANKSHAFT SERVICE
74. TRANSMISSION REASSEMBLY
76. CRANKSHAFT REMOVAL / INSTALLATION
77. ENGINE REASSEMBLY
78. PISTON INSTALLATION
79. CYLINDER INSTALLATION
80. PRIMARY DRIVE GEAR INSTALLATION
81. OUTLAW CAM TIMING EXPLODED VIEW
82. CYLINDER HEAD SERVICE
83. CYLINDER HEAD VALVE GUIDE / VALVE SEAT I...
84. VALVE SEAT RECONDITIONING
86. VALVE INSPECTION
87. ES50PL ADJUSTING PAD SELECTION MATRIX
88. CYLINDER HEAD ASSEMBLY
89. CYLINDER HEAD INSTALLATION
90. PISTON-TO-CYLINDER CLEARANCE
91. PISTON RING INSTALLED GAP
92. MECHANICAL SEAL REMOVAL AND INSTALLATION...
93. TROUBLESHOOTING
95. SPARK PLUG FOULING
97. FUEL SYSTEM AND CARBURETION
98. FUEL TANK ASSEMBLY
99. SPECIAL TOOLS
100. CV CARBURETOR SYSTEM
101. PILOT (IDLE AND SLOW) SYSTEM
102. STARTER SYSTEM (CHOKE OR ENRICHMENT)
103. MAIN SYSTEM
104. CARBURETOR DISASSEMBLY
105. CARBURETOR CLEANING
106. CARBURETOR ASSEMBLY
107. FUEL DELIVERY
108. FUEL PUMP
109. RICH MIXTURE
110. BODY / STEERING / SUSPENSION
112. GENERAL INFORMATION
113. BODY ASSEMBLY
114. BODY COMPONENT REMOVAL
115. HEEL POCKET
116. STEERING ASSEMBLY EXPLODED VIEW
117. STEERING KNUCKLE
118. INSTALLATION
119. FRONT HUB
120. HUB REMOVAL
121. HUB DISASSEMBLY
122. HUB INSTALLATION
123. FRONT SUSPENSION EXPLODED VIEW
124. FRONT A-ARM REPLACEMENT
125. REAR SUSPENSION EXPLODED VIEW
126. REAR A-ARM REPLACEMENT
127. A-ARM INSTALLATION
128. REAR HOUSING
129. HOUSING REMOVAL
130. HOUSING DISASSEMBLY / SERVICE
132. ASSEMBLY
133. INSTALLATION
134. REAR BEARING CARRIER
135. CARRIER ASSEMBLY
136. CARRIER INSTALLATION
137. REAR DRIVE (CV) JOINT
138. CV BOOT REPLACEMENT
139. CV JOINT INSTALLATION
140. DECALS
141. FRONT SHOCK EXPLODED VIEW
142. REAR SHOCK EXPLODED VIEW
143. RYDE FX™ SHOCK SERVICE
144. RydeFX™ Shock Rebuild Procedure
151. General specifications
152. BRAKE CALIPER EXPLODED VIEWS
153. BRAKE SYSTEM OVERVIEW
154. REAR BRAKE SYSTEM - EXPLODED VIEW
155. SERVICE NOTES
156. HYDRAULIC SYSTEM OPERATION
157. BRAKE FLUID REPLACEMENT AND BLEEDING PRO...
159. MASTER CYLINDER
160. INSTALLATION
161. FRONT CALIPER SERVICE
162. CALIPER INSPECTION
163. CALIPER REASSEMBLY
164. FRONT BRAKE PADS
165. PAD ASSEMBLY
166. FRONT BRAKE DISC
167. REAR CALIPER SERVICE
168. CALIPER INSPECTION
169. REAR BRAKE PAD
170. PAD INSTALLATION
171. REAR BRAKE DISC
172. DISC REMOVAL
173. TROUBLESHOOTING
175. GENERAL INFORMATION
176. LIGHTING AND CONTROLS
177. HEADLIGHT ADJUSTMENT
178. BRAKE LIGHT SWITCH TESTS
179. TETHER SWITCH TEST (ACCESSORY OPTION)
180. IGNITION SYSTEM
181. FLYWHEEL IDENTIFICATION
182. IGNITION SYSTEM TESTING
183. COMPONENTS OF DC / CDI IGNITION
184. COOLING SYSTEM
185. COOLANT FAN CONTROL SWITCH OPERATION TES...
186. CHARGING SYSTEM "BREAK EVEN" TEST
187. CHARGING SYSTEM TESTING FLOW CHART
188. BATTERY SERVICE
189. BATTERY TERMINALS / BOLTS
190. CHARGING PROCEDURE
191. CLUTCH SWITCH TEST
192. BRUSH INSPECTION / REPLACEMENT
193. STARTER REASSEMBLY
194. STARTER SYSTEM TESTING FLOW CHART

Description

The Service Manual of the Polaris Outlaw 500 and Outlaw 500 2006, Outlaw 500 2007 Offroad Vehicle provides necessary information for proper service and maintenance of this vehicle. It contains a Vehicle Identification section for the identification of the vehicle and its components, as well as a Standard Torque Specifications section for the correct torque values of the various fasteners. The Specifications section consists of data on the vehicle’s dimensions, engine specifications, and performance characteristics. The Service Manual also contains a detailed description of the electrical system and its components. It provides important safety precautions, instructions for the removal and installation of components, and a troubleshooting guide. The Service Manual also includes a wiring diagram and an exploded view of the vehicle, as well as instructions for the periodic maintenance of the vehicle. The Service Manual is an invaluable tool for the proper maintenance and repair of the Polaris Outlaw 500.

Also for: Outlaw 500 2006, Outlaw 500 2007

File size: 8.82 MB

Created: January 31, 2023

Last updated: March 23, 2023