Polaris Outlaw 500 Service Manual
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Polaris Outlaw 500 Service Manual

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Summary of Contents for Polaris Outlaw 500

  • Page 1 Fix it like a Pro...
  • Page 2 GENERAL INFORMATION MAINTENANCE ENGINE FUEL SYSTEM BODY / STEERING / SUSPENSION BRAKES ELECTRICAL WIRE DIAGRAMS...

  • Page 4: Table Of Contents

    2006-2007 OUTLAW 500........

  • Page 5: Vehicle Identification

    Should both keys become lost, replacement of the ignition switch assembly is necessary. Whenever corresponding with Polaris about a particular issue, the machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the left side of the frame tube.

  • Page 6: Standard Torque Specifications

    GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

  • Page 7: Specifications

    GENERAL INFORMATION SPECIFICATIONS MODEL: 2006- 2007 OUTLAW 500 MODEL NUMBER: A06(07)GP50AA,AB ENGINE MODEL: ES500PLE041 Category Dimension Length 71.5 in. / 182 cm Width 47.5 in. / 121 cm Height 45 in. / 114 cm Minimum Turing Radius 67 in. / 170 cm Wheel Base 51 in.

  • Page 8: 2006-2007 Outlaw 500

    GENERAL INFORMATION 2006 - 2007 OUTLAW 500 Drivetrain MODEL NUMBER: A06(07)GP50AA,AB Transmission Type Manual 5 speed Main Sprocket - # Tooth ENGINE MODEL: ES500PLE041 Rear Sprocket - # Tooth Engine Gear Ratio : 1st 2.43 1.61 Platform Fuji DOHC 4 stroke 1.29...

  • Page 9: Special Tools

    Carburetor Float Adjustment Tool PS-45259 Gas Fill Tool PS-45261 IFP Positioning / Extraction Tool PA-48282 Rear Hub Tool PV-43568 Fluke™ 77 Digital Multimeter 2870630 Timing Light *Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657). RepairPro Service Manual...

  • Page 10: Special Tool Listing

    Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Tools shown may not apply to a particular vehicle. Polaris recommends the use of Polaris special tools when servicing any Polaris product.
  • Page 11 GENERAL INFORMATION Standard Tools and Engine Tools 2871283 - Crank/Water Pump Seal Install Kit 2870303 - Hone Kit Suspension Tools 2870305 - Stone Replacement Kit PS-45261 - Shock IFP Positioning / Extraction Tool 2870588 - Hone Oil (12 OZ.) PS-45259 - Gas Fill Tool 2200634 - Valve Seat Reconditioning Kit Final Drive 2870459 - Dial Indicator...
  • Page 12 GENERAL INFORMATION Fuel & Brake Systems Electrical Tools 2870630 - Timing Light 2870975 - Mity Vac™ Electrical Tools 2871745 - Static Timing Light Harness PV-43568 - Fluke™ 77 Multimeter 2460761 - Hall Sensor Probe Harness PV-39617 - Current Clamp PV-39991 - Peak Reading Adapter 2870836 - Battery Hydrometer PV-37453 - Christie™...

  • Page 13: Misc. Numbers / Charts

    GENERAL INFORMATION MISC. NUMBERS / CHARTS Decimal Equivalents 1/64 ....0156 SAE Tap / Drill Sizes 1/32 ....0312.

  • Page 14: Coversion Table

    GENERAL INFORMATION Coversion Table Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x.0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 15: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.

  • Page 16: Maintenance

    LUBRICANTS AND SERVICE PRODUCTS ........2.9 POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS ... . 2.9 GENERAL VEHICLE INSPECTION AND MAINTENANCE.
  • Page 17 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.22 BATTERY MAINTENANCE .

  • Page 18: Periodic Maintenance Chart

    If oil level begins to rise, discontinue use and determine cause.) E= Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death.

  • Page 19: Pre-Ride Maintenance Interval

    Post-Ride Replace if damaged. Burp if bulging. Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service ( California) Have an authorized Polaris dealer perform these services. Recommended Pre-Ride Fluid Level Checks ITEM TYPE...

  • Page 20: Brakes

    Cooling System 50 H 500 (800) pressure test system yearly Steering 50 H 500 (800) Lubricate Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 21: 50 - 100 Hour Maintenance Interval

    Disassemble, clean, inspect bearings and seals, 100 H 12 M 1000 (1600) Needle Bearings (E) grease, reassemble Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. RepairPro Service Manual...

  • Page 22: 100 - 300 Hour Maintenance Interval

    Adjust as needed Inspect periodically; Toe Adjustment adjust when parts are replaced Headlight Aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 23: Maintenance References

    Transmission proper level. every 10hrs / 100mi. ** Fill master cylinder reservoirs Polaris DOT 3 or DOT 4 As required. Change fluid every Brake Fluid to indicated level inside Brake Fluid 2 years or 200 hours. *** reservoir.

  • Page 24: Lubricants And Service Products

    MAINTENANCE LUBRICANTS AND SERVICE PRODUCTS Polaris Lubricants, Maintenance and Service Products PART NO. DESCRIPTION ENGINE LUBRICANT 2874414 Engine Oil (Quart) PS 4 Synthetic (4-Cycle) 2874415 Engine Oil (Gallon) PS 4 Synthetic (4-Cycle) GREASE / SPECIALIZED LUBRICANTS 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz.

  • Page 25: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION FUEL SYSTEM AND AIR INTAKE AND MAINTENANCE Fuel System Pre-Ride / Daily Inspection WARNING Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. Gasoline is extremely flammable and • Tires – check condition and pressures explosive under certain conditions.

  • Page 26: Vent Lines

    MAINTENANCE Replace all fuel lines every two years. Turn valve on, start engine and inspect for leaks. Vent Lines Carburetor Draining Check engine, fuel tank, oil tank, and carburetor vent lines for The carburetor float bowl should be drained periodically, or signs of wear, deterioration, damage, or leakage.

  • Page 27: Carburetor Pilot Screw Adjustment

    With engine off, turn pilot screw in (clockwise) until lightly seated. Turn screw out the specified number of turns. Pilot Screw Initial Setting: Outlaw 500 - 2.5 Turns Out Start engine and warm it up thoroughly. Adjust idle speed by turning the idle adjustment screw in...

  • Page 28: Throttle Cable / Electronic Throttle Control (Etc) Adjustment

    MAINTENANCE To remove the ETC cover: Turn adjuster until 1/16” to 1/8” (1-2mm) freeplay is achieved at thumb lever. After making adjustments, Use a medium flat blade screwdriver and insert blade into quickly actuate the thumb lever several times and reverify the pocket of the cover starting on the #1 position freeplay.

  • Page 29: Air Box Drain Tube

    MAINTENANCE The pre filter should be cleaned before each ride using the Air Box Drain Tube following procedure: Periodically check the air box drain tube located on the bottom side of the air box. Be sure the drain tube is not obstructed by Unlatch and remove the seat.

  • Page 30: Engine Oil And Filter Service

    Remove the dipstick and check the oil level. Maintain the oil level in the safe range, between the full and add marks. Do not overfill. Reinstall the dipstick. Engine Oil and Filter Service IMPORTANT: Polaris PS-4 Engine 72–78 in. lbs. recommended for use in the Predator. PS-4 was specifically designed for the Predator’s engine and...

  • Page 31: Oil Pump Priming Procedure

    18. Remove the dipstick and fill the oil tank with 2.25 quarts Cylinder Compression w / decompression (1.9 l) of Polaris PS-4 Engine Oil (PN 2874414). Standard: 85-90 PSI @ 400 RPM 19. Place gear selector in neutral and set parking brake.

  • Page 32: Engine Mount Locations

    MAINTENANCE Periodically clean the spark arrestor to remove accumulated arrestor is damage is found. carbon. Verify which type of spark arrestor your ATV is equipped with and follow the appropriate cleaning procedure below: (A) or (B) Inspect the screen Procedure A - End Cap Spark Arrestor Remove the three screws (1) and remove the arrestor (2) from the end of the muffler.

  • Page 33: Coolant Strength / Type

    Radiator hose clamp torque is 36 in.lbs. (4 Nm). • Polaris Premium 60/40 anti-freeze is premixed and ready to use. Do not dilute with water. Radiator Check radiator external air flow passages for restrictions or Coolant Strength / Type damage.

  • Page 34: Cooling System Pressure Test

    MAINTENANCE Fill reservoir to upper mark with Polaris Premium 60/40 Squeeze the lever fully and release. Slightly squeeze the Anti Freeze / Coolant (PN 2871323) or a mixture of lever again until a slight resistance is felt. Measure the antifreeze and distilled water as required for freeze freeplay again.

  • Page 35: Drive Chain Inspection / Replacement

    O–Rings may occur. Clean chain with hot soapy water and a soft bristled nylon brush. Do not press Polaris ATV drive chains are equipped with O–ring sealed plate in too far permanently greased pins and rollers.The sprockets and outer rollers require periodic lubrication.

  • Page 36: Drive Chain Adjustment

    MAINTENANCE Drive Chain Adjustment Rear Driveshaft Boot Inspection Before Operating Loosen the upper and lower pivot mounting bolts (1). Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, replacement is required. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension.

  • Page 37: Rear Driveshaft Boot "Pressure Equalizing

    MAINTENANCE Rear Driveshaft Boot “Pressure Equalizing” ELECTRICAL AND IGNITION SYSTEM Using a needle nose pliers or boot clamp removal tool, Battery Maintenance remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the WARNING boot.

  • Page 38: Battery Inspection / Removal

    Coat terminals and bolt threads with Dielectric Grease (PN 2871329). Reinstall battery cover, holder strap and front cab. Battery Terminals / Bolts Ensure battery terminals are clean of corrosion. Use Polaris corrosion resistant Dielectric Grease (PN 2871329) on battery bolts. 2.23...

  • Page 39: Spark Plug Inspection

    MAINTENANCE Charge with a charging output no larger than 1/10 of the Remove spark plug. and inspect electrodes for wear and battery's amp/hr rating. Charge as needed to raise the open carbon buildup. The insulator tip should be a light tan color, circuit voltage to 12.9 V or greater.

  • Page 40: Controls

    Severe injury or death can result from improper toe alignment and adjustment. Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component Position the vehicle on a level surface. repair and adjustment be performed by an authorized...

  • Page 41: Steering Inspection / Tie Rod Ends And Hubs

    MAINTENANCE Measure the distance between the string in front of the rear • Repeat inspection for inner tie rod end on steering post. tires (A) and in front of the front tires (B). If the two measurements are not equal, adjust the string position until the measurements are equal.

  • Page 42: Toe Alignment Adjustment

    ATV, which could result in an accident and serious CAUTION injury or death. Always adjust both the left and right spring preloads equally or have your Polaris During tie rod adjustment, it is very important that dealer perform the adjustments.
  • Page 43 MAINTENANCE Subtract the step 8 measurement from the step 4 Rear Suspension Set-Up measurement. The difference should be between 3.75 and Position the vehicle on a level surface. 4 inches (9.5 - 10.2 cm). Stop the engine. 10. If the number is less than 3.75 inches (9.5 cm), decrease the Elevate the rear of the vehicle by placing a suitable stand front spring preload and repeat all steps (See “Front Spring under the frame.

  • Page 44: Rear Shock Compression Adjustment

    • Keep fluid level in the master cylinder reservoir to the indicated level inside reservoir. • Use Polaris DOT 3 or DOT 4 Brake Fluid Rear Shock Compression Adjustment Parking Brake...

  • Page 45: Hose / Fitting Inspection

    MAINTENANCE • Check surface condition of the disc. Free Play: ″ ″ • Inspect thickness of brake pad friction material. Free play of the brake pedal should be 1/8 – 1/4 (3.2 – 6.35 mm). Hose / Fitting Inspection If free play is excessive, inspect pedal (1), linkage, and master Check brake system hoses and fittings for cracks, deterioration, cylinder (2) for wear or damage and replace any parts as needed.

  • Page 46: Tire Pressure

    MAINTENANCE Securely tighten the wheel nuts to the proper torque listed Tire Tread Depth in the table. ″ Always replace tires when tread depth is worn to 1/8 (3 mm) CAUTION or less. WARNING Improperly installed wheels could affect vehicle handling and tire wear.
  • Page 47 MAINTENANCE NOTES 2.32 RepairPro Service Manual...
  • Page 48 ENGINE CHAPTER 3 ENGINE SPECIFICATIONS ............3.3 TORQUE SPECIFICATIONS .
  • Page 49 ENGINE ENGINE REASSEMBLY ..........3.30 CRANKCASE REASSEMBLY .

  • Page 50: Specifications

    ENGINE SPECIFICATIONS Torque Specifications ES50PL Fastener Thread ES50PL: Ft. Lbs. (Nm) Blind Plug (Crankcase) 1/8 PT 6.6–11.1 (9–15 Nm) Blind Plug (Oil Filter Cover) 1/4 PT 12.5–17 (17–23 Nm) Bearing Stop Plates 8.1–9.6 (11–13 Nm) Camshaft Chain Tensioner Blade Bolt 10–12.2 (13.5–16.5 Nm) Camshaft Chain Tensioner 6.6–8.1 (9–11 Nm)

  • Page 51: Es50Pl Engine Service Data

    ENGINE ES50PL Engine Service Data Cylinder Head / Valve ES50PL 1.667–1.671” (42.35–42.45 mm) Limit 1.655” (42.05 mm) Cam lobe height 1.667–1.671” (42.35–42.45 mm) Limit 1.655” (42.05 mm) .9821–.9828” (24.946–24.963 mm) Camshaft journal OD Camshaft .8652–.8655” (21.976–21.985 mm) .9842–.9851” (25.000–25.021 mm) Camshaft journal bore ID .8657–.8661”...
  • Page 52 ENGINE ES50PL Engine Service Data Cylinder / Piston / Connecting Rod / Crankshaft ES50PL Surface warpage limit (mating with cylinder head) .002” (.05 mm) Cylinder bore 3.9055–3.9062” (99.20–99.22 mm) Taper limit .002” (.05 mm) Cylinder Out of round limit .002” (.05 mm) .0018- .0025”...

  • Page 53: Special Tools

    ENGINE Special Tools GENERAL ENGINE SERVICE Piston Identification PART NUMBER TOOL DESCRIPTION Water Pump Mechanical 2872105 The piston may or may not have an identification mark for Seal Puller piston placement. If the piston has an identification mark, follow Valve Seat Reconditioning 2200634 the directions for piston placement below.

  • Page 54: Coolant Temperature Sensor (Thermistor)

    Allow the engine and cooling system to cool possible engine damage. Polaris Premium 60/40 before servicing. Antifreeze / Coolant (PN 2871323) is recommended for use in all cooling systems and comes pre–mixed, Radiator Cap / System Pressure Test ready to use.

  • Page 55: Accessible Components

    ENGINE Accessible Components Engine Removal The following components can be serviced or removed with Thoroughly clean the ATV engine and chassis. the engine installed in the frame: Clean work area. Support the ATV with jackstands under the footrests at a •...

  • Page 56: Engine Installation Notes

    Engine Installation Notes Engine Break In Period The break in period for a Polaris ATV engine is defined as the After the engine is installed in the frame, review this checklist first ten hours of operation, or the time it takes to use two full and perform all steps that apply: tanks of gasoline.

  • Page 57: Crankshaft Straightening

    14.8 - 17 ft. lbs. (20-23 Nm) HIGH .005 (.13 mm) (If fitting is removed, follow oil pump priming procedure). Oil Pressure Specification: 20 PSI @ 5500 RPM, Polaris PS-4 Synthetic (Engine Hot) Oil Pressure Test Remove blind plug on front right oil filter cover.

  • Page 58: Oil Pump Priming Procedure

    ENGINE Oil Pump Priming Procedure Oil Flow - ES50PL NOTE: The oil pump priming procedure should be The chart on Page 3.12 describes the flow of oil through the performed as a safeguard against loss of pump ES50PL engine. Beginning at the oil tank, the oil flows through prime when repairing oil tank, lines or engine.

  • Page 59: Es50Pl Oil Flow Chart

    ENGINE ES50PL Oil Flow Chart Top of Oil Tank Oil Pump Crankcase (Clutch Side) Oil Tank Oil Hose Crankcase (Mag Side) (Scavenging) Oil Gallery Oil Gallery Oil Hose Oil Strainer Crankcase (Mag Side) Crankcase Oil Gallery Cylinder Cam Chain Cam & Crank Sprocket Piston Crankcase (Clutch Side) Oil Gallery...

  • Page 60: Es50Pl Engine Exploded Views

    ENGINE ES50PL Engine Exploded Views Crankcase / Transmission Cylinder / Cylinder Head Crankshaft and Piston Valve Train 3.13...

  • Page 61: Upper Engine Disassembly

    ENGINE UPPER ENGINE DISASSEMBLY If tensioner remains in place, tap lightly on tensioner body with a soft face hammer and remove tensioner. Disassembly CAUTION REFER TO PAGE 3.8-3.9 FOR ENGINE REMOVAL / INSTALLATION NOTES The assembly is under spring tension. Maintain inward pressure while removing.

  • Page 62: Camshaft Removal

    ENGINE To retract the plunger, rotate the special tool clockwise To free the cam assembly, lift one cam assembly and while holding the tensioner stationary. You may also hold slightly rotate it while removing the chain from the cam the special tool stationary and rotate the tensioner assembly gear.

  • Page 63: Camshaft Inspection

    ENGINE Camshaft Inspection Measure ID of camshaft journal bore. Visually inspect each cam lobe for wear, chafing or Camshaft Journal I.D.: damage. NOTE: Camshafts, gears and bearings are not Mag End: .9842- .9851ð serviceable. Replace camshaft as an assembly if (25.00- 25.021 mm) problems are found.

  • Page 64: Cylinder And Piston Removal

    ENGINE Cylinder and Piston Removal Rock cylinder forward and backward and lift it from the crankcase, exposing the piston and connecting rod. Support NOTE: Follow engine disassembly procedures to piston with Piston Support Block (PN 2870390). remove valve cover, camshafts and cylinder head. Remove dowel pins from crankcase.

  • Page 65: Piston And Rod Inspection

    ENGINE Repeat procedure for second ring. Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge. The oil control ring is a three piece design consisting of a Replace piston and rings if ring–to–groove clearance top and bottom steel rail and center expander section.

  • Page 66: Lower Engine Disassembly

    ENGINE LOWER ENGINE DISASSEMBLY Measure the ID of the bushing in the stator housing (A) and the crankcase and record. Measure in two directions 90° apart to determine if cover is out of round. Replace cover Crankcase Disassembly and Inspection if clearance is determined to be excessive.

  • Page 67: Crankshaft Nut Removal

    ENGINE Removing the flywheel exposes the starter drive main gear Crankshaft Nut Removal and one way clutch, which is mounted on the flywheel. Remove the stator-side crankshaft nut using MAG End Inspect the main gear and bearing for wear, broken teeth or Crankshaft Nut Remover/Installer (PN PA-46076) while other damage.
  • Page 68 ENGINE Inspect or replace the crankshaft oil seal anytime the clutch Remove the clutch plates and friction discs, keeping them cover is removed for service. Install with the seal lip in order. Inspect the pressure plates for wear and warpage. pointed in toward the cover.

  • Page 69: Shifter Component Removal And Inspection

    ENGINE Shifter Component Removal and Inspection Inspect the ratcher pawls (F), pawl plungers (G), plunger springs (H), shifter collar (J), shifter drum (K) and guide With the clutch basket removed, remove the shift shaft plate (L) for wear or damage. Replace if wear or damage assembly (A), guide plate (D), pawl assembly (B), and is evident.

  • Page 70: Oil Pump Removal And Inspection

    ENGINE Oil Pump Removal and Inspection NOTE: Dowel pins for the inner pump body are loose and may become lost. Keep pins in a secure Remove the circlip holding the oil pump gear and remove location. the gear. Remove the 3 bolts holding the oil pump cover. Inspect the inside of the cover for wear or scoring.

  • Page 71: Cam Chain / Tensioner Blade Removal

    ENGINE Remove the cam gear and thrustwasher from the crankshaft Crankcase Separation for inspection. Replace if damage or excessive wear is Remove the 13 flange bolts. 12 from the magneto side and present to the gear teeth or splines. 1 from the clutch side of the crankcase evenly in a criss– Installation: Reverse the procedures and torque nut to 81–...

  • Page 72: Crankcase Inspection

    ENGINE Separate crankcase by tapping with a soft faced hammer in NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected reinforced areas. Watch the gap along the crankcase mating surface, making sure to separate the crankcase evenly. It visually, and by feel.

  • Page 73: Transmission And Crankshaft Service

    ENGINE TRANSMISSION AND CRANKSHAFT Inspect the shaft support bearings in the crankcase halves. Replace if any roughness or wear is felt. See page 3.25 for SERVICE crankcase bearing inspection / removal. Transmission Removal and Inspection To reassemble, reverse the procedures using the photos for reference.

  • Page 74: Transmission Reassembly

    ENGINE To reassemble the main shaft, install the components in the Insert the output shaft assembly, minus the outer gear into order removed. the stator side casehalve. Do not insert outer gear or shift fork pins at this time. Before pressing the reverse gear onto the main shaft, heat the reverse gear in an oil bath if desired.
  • Page 75 ENGINE Install the main shaft assembly. The outer gear can now be Insert and rotate the shift drum so the alignment pin is installed. Verify the shallow side of the outer gear is facing approximately at the 5 o’clock position. Insert the fork pins out during installation.

  • Page 76: Crankshaft Removal / Installation

    ENGINE Crankshaft Removal / Installation Using MAG End Crankshaft Installer (PA-46077), draw the crankshaft into the bearing assembly by sliding the To remove crankshaft: collar and thrustwasher over the crankshaft end, threading the inner puller onto the crankshaft end. Turn the outer nut Remove the crankshaft retaining nut using Crankshaft Nut clockwise while holding the inner to pull the crankshaft into Remover / Installer (PA-46076).

  • Page 77: Engine Reassembly

    ENGINE Place the crankshaft in a truing stand or V–blocks and Reassemble crankcase halves. This best measure the runout on both ends with a dial indicator. See accomplished with the stator side casehalve settled in a Crankshaft Straightening on Page 3.10. suitable fixture that allows it to lay flat.

  • Page 78: Piston Installation

    ENGINE Piston Installation Piston Ring Installation NOTE: Apply clean engine oil to all ring surfaces Clean the gasket surfaces on the cylinder and crankcase. Remove all traces of old gasket material. and ring lands. Always check piston ring installed Make sure the cylinder mounting bolt holes are clean and gap before rings are installed on piston.

  • Page 79: Cylinder Installation

    ENGINE Cylinder Installation Cam Chain Installation Place the dowel pins in the crankcase and install a new NOTE: The camshafts, crankshaft sprocket and clutch basket must be removed to perform this cylinder base gasket. procedure. Install the cam chain by dropping it down through the chain room and over the crankshaft sprocket.

  • Page 80: Primary Drive Gear Installation

    ENGINE If not already at Top Dead Center, Loosely hold the cam Re-check all cam timing marks to verify proper cam timing, chain and rotate the crankshaft until the crankshaft cam and install the cam tower. Tighten the bolts evenly in a sprocket timing mark is aligned with the Top Dead Center criss-cross pattern to specification.

  • Page 81: Outlaw Cam Timing Exploded View

    ENGINE Outlaw Cam Timing Exploded View 3.34 RepairPro Service Manual...

  • Page 82: Cylinder Head Service

    ENGINE CYLINDER HEAD SERVICE Cylinder Head Disassembly Cylinder Head Inspection WARNING Wear eye protection during cylinder head disassembly and reassembly. Remove the valve buckets (A). NOTE: Keep all parts in order with respect to their location in the cylinder head. Use care not to mar or damage the buckets upon removal.

  • Page 83: Cylinder Head Valve Guide / Valve Seat Inspection

    ENGINE NOTE: To prevent loss of tension, do not compress NOTE: Replace seals whenever the cylinder head is the valve springs more than necessary. disassembled. Hardened, cracked or worn valve seals will cause excessive oil consumption and carbon buildup. Remove spring retainer, inner and outer springs and spring washer.

  • Page 84: Valve Seat Reconditioning

    ENGINE Valve Seat Reconditioning IMPORTANT: Do not use a torch to heat cylinder head or warpage may result from uneven heating. Head Follow the manufacturers instructions provided with the temperature can be checked with a pyrometer or a Valve Seat Reconditioning Kit (P/N 2200634). Abrasive welding temperature stick.
  • Page 85 ENGINE • If the contact area of the cutter is in the same place, the valve guide is distorted from improper installation and must be replaced. Be sure the cylinder head is at the proper temperature and replace the guide. Seat Contact •...

  • Page 86: Valve Inspection

    ENGINE Valve Inspection Remove all carbon from valve with a soft wire wheel. Check valve face for runout, pitting, and burned spots. To check for bent valve stems, mount the valve in “V” blocks and use a dial indicator. Check end of valve stem for flaring, pitting, wear or damage (A).

  • Page 87: Es50Pl Adjusting Pad Selection Matrix

    ENGINE ES50PL Adjusting Pad Selection Matrix Measure valve clearance at TDC (Compression Stroke) using thickness gauge with original adjusting pad installed. Reference the measurement and the 3 digits marked on the existing adjusting pad on the matrix below. Select a suitable adjusting pad from the matrix below and replace existing pad. Measure and confirm that valve clearance is within the standard values.

  • Page 88: Cylinder Head Assembly

    ENGINE Cylinder Head Assembly Place spring retainer on and install valve spring compressor (A). Compress springs only enough to allow split keeper installation and prevent loss of spring tension. Install split CAUTION keepers with the gap even on both sides. Wear eye protection during assembly.

  • Page 89: Cylinder Head Installation

    ENGINE Cylinder Head Installation CYLINDER SERVICE Clean the gasket surfaces on the cylinder head and cylinder. Cylinder Inspection Remove all traces of old gasket material. Refer to disassembly photos. Remove all gasket material from the cylinder sealing surfaces. Install the cam chain tensioner guides. Be sure bottom end Inspect the top of the cylinder for warp using a straight edge of guide is located properly in crankcase.

  • Page 90: Piston-To-Cylinder Clearance

    Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust. Honing To Deglaze A finished cylinder should have a cross–hatch pattern to ensure...

  • Page 91: Piston Ring Installed Gap

    ENGINE If cylinder wear or damage is excessive, it will be necessary to If the bottom installed gap measurement exceeds the replace the cylinder. Hone only enough to deglaze the outer service limit, replace the rings. If ring gap is below layer of the cylinder bore.

  • Page 92: Mechanical Seal Removal And Installation (Engine Assembled)

    ENGINE Mechanical Seal Removal and Installation Slide the main puller body over the outer portion of the (Engine Assembled) mechanical seal as shown in (Figure 3-45)and turn T– Handle clockwise until it contacts water pump shaft. The Water Pump Mechanical Seal Puller allows a technician to Continue rotating until outer portion of mechanical seal is replace the seal on ES50PL engines without removing the separated from the metal seal body.

  • Page 93: Troubleshooting

    ENGINE Turn the puller T–Handle clockwise until it contacts the TROUBLESHOOTING water pump shaft. Continue rotating until the remaining portion of mechanical seal has been removed from the case. Engine (Figure 3-48) Engine Turns Over But Fails to Start • No fuel •...
  • Page 94 ENGINE Engine Idles But Will Not Rev Up Low Compression • Spark plug fouled/weak spark • Decompressor stuck • Broken throttle cable • Cylinder head gasket leak • Obstruction in air intake • No valve clearance or incorrectly adjusted • Air box removed (reinstall all intake components) •...

  • Page 95: Spark Plug Fouling

    ENGINE Spark Plug Fouling • Restricted system (mud or debris in radiator fins or restriction to air flow, passages blocked in radiator, • Spark plug cap loose or faulty lines, pump, or water jacket) • Choke cable adjustment or plunger/cable sticking •...
  • Page 96 FUEL SYSTEM / CARBURETION CHAPTER 4 FUEL SYSTEM / CARBURETION FUEL SYSTEM AND CARBURETION ........4.2 BSR 42 CARBURETOR EXPLODED VIEW.

  • Page 97: Fuel System And Carburetion

    FUEL SYSTEM / CARBURETION FUEL SYSTEM AND CARBURETION BSR 42 Carburetor Exploded View Description Description Description Description Cover, Diaphragm 16 Guide, Cable 31 A-Float 46 Asm., Plunger Spring 17 O-ring 32 Jet, Main 47 Spring Diaphragm 18 Cover 33 Ring 48 Holder, Guide Valve, Piston 19 Screw...

  • Page 98: Fuel Tank Assembly

    FUEL SYSTEM / CARBURETION Fuel Tank Assembly Tank Cap Vent Line Fuel Tank Fuel Valve Fuel Lines Impulse Line Fuel Pump In-Line Filter FUEL FLOW Fuel Tank Vent Fuel Tank Fuel Screens Fuel Valve *Fuel Pump (Filter in Pickup) Carburetor Vent Carburetor Engine In-Line Filter...

  • Page 99: Special Tools

    FUEL SYSTEM / CARBURETION Special Tools Polaris ATV carburetors are calibrated for an altitude of 0–6000 ft. (0–1800 meters) and ambient temperatures above +40 TOOL (+26 C). Carburetors must be re–calibrated if operated outside PART NUMBER DESCRIPTION this temperature and/or altitude range. The jetting installed in production is not intended for all altitudes and/or temperatures.

  • Page 100: Cv Carburetor System

    FUEL SYSTEM / CARBURETION CV CARBURETOR SYSTEM Vent Systems – CV Carburetor The carburetor float bowl vent lines supply atmospheric Carburetor Function pressure to the float bowl. The lines must be free of kinks, restrictions and be properly routed. This allows fuel to flow in Carburetor Component Function the proper amount and prevents contaminants from entering the Main...

  • Page 101: Pilot (Idle And Slow) System

    FUEL SYSTEM / CARBURETION Mikuni CV Carburetor Operation, Continued..Pilot (Idle and Slow) System When the throttle plate is opened and engine speed begins to This system supplies fuel during engine operation with throttle increase, the pressure in the venturi, and therefore in the valve closed (1) or slightly opened.

  • Page 102: Starter System (Choke Or Enrichment)

    FUEL SYSTEM / CARBURETION Starter System (Choke or Enrichment) Float System When the choke cable (1) is activated, the starter plunger (5) is Fuel enters the float chamber (3) by means of the inlet pipe and lifted off the seat. passage, through a screen on the back of the inlet needle seat (4), and around the inlet needle (2).

  • Page 103: Main System

    FUEL SYSTEM / CARBURETION Main System Pilot Screw As throttle valve (1) is opened, engine speed rises, and this The pilot system supplies fuel during engine operation with the increases negative pressure in the venturi. Consequently the throttle valve closed or slightly opened. The fuel/air mixture is vacuum slide (2) moves upward.

  • Page 104: Carburetor Disassembly

    FUEL SYSTEM / CARBURETION Carburetor Disassembly Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. Use the following disassembly, assembly, and inspection NOTE: Do not use a pliers to remove the seat or techniques to service a CV carburetor. permanent damage may occur.

  • Page 105: Carburetor Cleaning

    FUEL SYSTEM / CARBURETION Carburetor Cleaning Carburetor Inspection Inspect jet needle and needle jet for wear. Look for WARNING discoloration, shiny spots, or an area that looks different than the rest of the needle. The middle to upper portion of the needle contacts the needle jet and is the most likely Protect eyes from contact with cleaner.

  • Page 106: Carburetor Assembly

    FUEL SYSTEM / CARBURETION Carburetor Assembly NOTE: The final pilot (idle) mixture must be adjusted with the engine running. Refer to Chapter 2 for Inspect the diaphragm (A) for holes, deterioration, or damage. procedure. Make sure the diaphragm is pliable but not swollen. The diaphragm should fit properly in the carburetor body.

  • Page 107: Fuel Delivery

    FUEL SYSTEM / CARBURETION If the float is past parallel with the mating surface, the FUEL DELIVERY carburetor has been tilted back too far and the float tongue is likely compressing the needle valve pin. Needle and Seat Leak Test Float too far inward Install the float bowl.

  • Page 108: Fuel Pump

    FUEL SYSTEM / CARBURETION Fuel Pump Inspection / Assembly Open bowl drain screw by turning counterclockwise approximately two turns. Start and run engine for 3 to 5 Inspect inlet and outlet check valves for cracks, warpage or seconds to allow fuel level to stabilize in the line. If level damage.

  • Page 109: Rich Mixture

    FUEL SYSTEM / CARBURETION • Ruptured vacuum slide diaphragm, vacuum slide stuck Idle Too Low closed or sticky • Choke cable bending or incorrectly adjusted • Improper spring • Idle speed set incorrectly • Jet needle position incorrect • Idle mixture screw adjusted incorrectly or damaged •...

  • Page 110: Body / Steering / Suspension

    BODY / STEERING / SUSPENSION CHAPTER 5 BODY / STEERING / SUSPENSION GENERAL INFORMATION ..........5.3 TORQUE SPECIFICATIONS .
  • Page 111 BODY / STEERING / SUSPENSION FRONT SHOCK EXPLODED VIEW ........5.32 RYDE FX™...

  • Page 112: General Information

    BODY / STEERING / SUSPENSION GENERAL INFORMATION COMPONENT TORQUE VALUE Torque Specifications SERVICEABLE COMPONENTS Rear Pivot Housing 30 ft. lbs. COMPONENT TORQUE VALUE Mounting Bolts (41 Nm) 26 ft. lbs. FRONT SUSPENSION Rear Sprocket Bolts (35 Nm) 33 ft. lbs. Brake Disc 18 ft.

  • Page 113: Body Assembly

    BODY / STEERING / SUSPENSION BODY ASSEMBLY Exploded View A. Seat I. Grab Bar B. Seat Release Latch J. Fuel Tank Cover C. Rear Cab K. Frame D. Side Panel L. Foot Peg E. Front Cover M. Rock Guard F. Front Cab N.

  • Page 114: Body Component Removal

    BODY / STEERING / SUSPENSION BODY COMPONENT REMOVAL Remove the 2 torx head screws holding the lower front portion of the front cab. Seat / Side Panel Remove the seat by lifting up on the releasing latch and slide the seat towards the rear of the ATV. Remove the 2 torx head screws from the side panel.

  • Page 115: Heel Pocket

    BODY / STEERING / SUSPENSION Remove the fuel tank cap to allow the cover to be removed. Rear Cab Once removed reinstall the fuel tank cap. Remove the 2 bolts from the lower portion of the rear cab on each side as shown below. Reverse the removal steps to reinstall the tank cover.

  • Page 116: Steering Assembly Exploded View

    BODY / STEERING / SUSPENSION STEERING ASSEMBLY EXPLODED VIEW A. Handlebar 9 ft. lbs B. Block Clamps (12 Nm) C. Steering Bushings D. Steering Post E. Zerk Fitting F. Cotter Pin G. Tie Rod Assembly H. Sealed Ball Bearing I. Ball Bearings J.

  • Page 117: Steering Knuckle

    BODY / STEERING / SUSPENSION STEERING KNUCKLE Tap down on the lower A-arm to move the lower ball joint from the steering hub. Removal Installation Follow the steps in the “FRONT HUB REMOVAL” Before installation check the condition of the ball joints. section to remove the hub, if needed.

  • Page 118: Installation

    BODY / STEERING / SUSPENSION Installation A driver must be used for the removal of the ball joints. Use the dimensions below to fabricate or locate the correct size Place the A-arm in the correct position for ball joint driver to use in the following process. installation.

  • Page 119: Front Hub

    BODY / STEERING / SUSPENSION FRONT HUB Exploded View Ref. Qty. Description Nut, Castle Pin, Cotter Washer Spacer, Outer Seal Bearing, Ball, Sealed Hub, Wheel, Front, Indy Red Stud Spacer, Tapered Bearing, Ball Seal Disc, Brake Spacer, Inner Bolt Rim, Front Valve, Rim Nut, Flange Tire, Front, 21x7–10...

  • Page 120: Hub Removal

    BODY / STEERING / SUSPENSION Hub Removal Remove outer brake disc guard, cotter pin, front spindle nut, and washer. Elevate front end of ATV and safely support machine under footrest / frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure.

  • Page 121: Hub Disassembly

    BODY / STEERING / SUSPENSION Hub Disassembly Hub Assembly Place a shop towel on hub to protect surface. Carefully pry Drive or press one new bearing into hub using a bearing seal out of hub. driver. Seals (2) Seal Tapered Spacer Bearings (2) Using a brass drift, tap bearing spacer to one side to expose CAUTION...

  • Page 122: Hub Installation

    BODY / STEERING / SUSPENSION Hub Installation Rotate hub. It should rotate smoothly without binding, rough spots or side play. Apply anti-seize compound to spindle area, this will aid in easier removal of the wheel in the future. Install brake caliper. Tighten bolts to 18 ft.lbs. (24 Nm). Inspect spindle and bearing surface for wear or damage.

  • Page 123: Front Suspension Exploded View

    BODY / STEERING / SUSPENSION FRONT SUSPENSION EXPLODED VIEW Use new cotter pins upon reassembly. open end toward rear of machine. Install with 33 ft. lbs. (45 Nm) 40 ft. lbs. (54 Nm) 40 ft. lbs. A. Springs (54 Nm) B.

  • Page 124: Front A-Arm Replacement

    BODY / STEERING / SUSPENSION FRONT A-ARM REPLACEMENT Examine A–arm shafts (I). Replace if worn. Discard hardware. A-arm Removal and Inspection Elevate and safely support vehicle. Remove the front wheel(s). Remove the upper and lower ball joint cotter pins (A) from the ball joint studs (B &...

  • Page 125: Rear Suspension Exploded View

    BODY / STEERING / SUSPENSION REAR SUSPENSION EXPLODED VIEW 33 ft. lbs. (45 Nm) 30 ft. lbs. (41 Nm) 33 ft. lbs. (45 Nm) 9 ft. lbs. (12 Nm) 33 ft. lbs. (45 Nm) 30 ft. lbs. (41 Nm) 33 ft. lbs. (45 Nm) A.

  • Page 126: Rear A-Arm Replacement

    BODY / STEERING / SUSPENSION REAR A-ARM REPLACEMENT NOTE: Rear A-arm mounts contain needle bearings A-arm Removal Elevate and safely support vehicle. Remove the rear wheel(s). Loosen the upper and lower hub carrier bolts at the wheel end of A–arms (A)(C). A-arm Inspection Disassemble, clean and inspect the upper A-arm bushings and shaft.

  • Page 127: A-Arm Installation

    BODY / STEERING / SUSPENSION Disassemble, clean and inspect the lower A-arm thrust NOTE: Apply grease to the inside of the needle washers, needle bearing, seals and shaft. Replace bearings before inserting shaft. components as required. Inspect Insert A–arm shafts, seals and thrust washers into the A– arm mounting bores.

  • Page 128: Rear Housing

    BODY / STEERING / SUSPENSION REAR HOUSING Exploded View CV Ball/Cage Assembly Individual Parts Not Available - Order Hub Assembly A. CV Boot Retaining Ring B. Inner CV Boot C. Sprocket Hub D. Bearing (2) E. Rear Axle Housing F. O-Ring G.

  • Page 129: Housing Removal

    BODY / STEERING / SUSPENSION Housing Removal Remove brake disc and drive sprocket from rear housing. This provides the necessary clearance for housing removal. With ATV on the ground, loosen wheel nuts and hub nuts. Safely lift and support the rear of the ATV under the main frame.

  • Page 130: Housing Disassembly / Service

    BODY / STEERING / SUSPENSION Housing Disassembly / Service Using a flat blade screwdriver, carefully pry the retaining rings from both CV ball cages. Place housing in a suitable holding fixture. Remove both boot clamps from their locations. Using a flat blade screwdriver, carefully pry the retaining ring from each boot.
  • Page 131 BODY / STEERING / SUSPENSION To disassemble the inner CV joint, place the CV end on a 11. To reassemble the inner CV joint, use special Hi Temp CV vise and use a punch to tap the driveshaft out. joint grease to allow the rollers to “stick” to the cage. Insert the rollers into the outer cage, then insert the inner joint sideways 180 degrees into the cage assembly and turn the inner joint to capture the rollers.

  • Page 132: Assembly

    BODY / STEERING / SUSPENSION 15. Using a suitable holding fixture, press or tap the carrier Using Special Tool PN PA-48282, press the rear hub bearings out the opposite end of each housing. assembly together. Verify o-ring is seated properly during reassembly.

  • Page 133: Installation

    BODY / STEERING / SUSPENSION Pack the housing assembly and inner boots with a total of Clean and apply a thin coat of sealant to both the boot and 8.75 oz. of Hi-Temperature CV joint grease. Distribute sealing surface before installing inner boots. Install grease evenly.

  • Page 134: Rear Bearing Carrier

    BODY / STEERING / SUSPENSION Carrier Disassembly / Inspection Insert and torque the a-arm mount bolts to 30 ft.lbs. (41 Nm). Remove outer snap ring. From the back side, tap on the outer bearing race with a drift Carrier Bolt Torque: punch in the reliefs as shown.

  • Page 135: Carrier Assembly

    BODY / STEERING / SUSPENSION Disassemble, clean and inspect the upper A-arm bushings Carrier Assembly and shaft. Replace components as required. Assemble and install the upper A-arm bushings and shaft. Disassemble, clean and inspect the lower A-arm thrust Install needle bearings by pressing the bearings into the washers, needle bearing, seals and shaft.

  • Page 136: Carrier Installation

    BODY / STEERING / SUSPENSION Support bottom of bearing carrier housing and start bearing Lift bearing carrier until top aligns with upper control arm. in housing Install and torque upper control arm bolt and torque to specification. Torque lower control arm bolts to specification.

  • Page 137: Rear Drive (Cv) Joint

    BODY / STEERING / SUSPENSION Install a new cotter pin. Tighten nut slightly to align holes Photo below is shown without shaft for clarity. Wipe if required. grease away from recess in CV joint inner hub and locate snap ring REAR DRIVE (CV) JOINT Snap Ring Located in Recessed Area CV Joint Removal...

  • Page 138: Cv Boot Replacement

    BODY / STEERING / SUSPENSION CV Boot Replacement Remove CV joint from end of shaft. Remove boot from shaft. Tabs face shaft NOTE: When replacing a damaged boot, check the grease for contamination by rubbing it between two fingers. A gritty feel indicates contamination. If the grease is not contaminated, the boot can be replaced without cleaning the CV joint.

  • Page 139: Cv Joint Installation

    BODY / STEERING / SUSPENSION While pulling out on the CV shaft, fully extend the CV joint CV Joint Installation and slide a straight O-ring pick or a small slotted screw Slide shaft assembly into bearing carrier hub. driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life.

  • Page 140: Decals

    BODY / STEERING / SUSPENSION DECALS Install rear wheel and torque wheel nuts to specification. 90 ft.lbs. (122 Nm) Replacement WARNING The following procedure involves the use of an open flame. Perform this procedure in a well ventilated area, away from gasoline or other flammable materials.

  • Page 141: Front Shock Exploded View

    BODY / STEERING / SUSPENSION FRONT SHOCK EXPLODED VIEW RydeFX™ FRONT SHOCK Ref. Description Ref. Description Bushing Sleeve Spring Retainer Nut IFP O-Ring Compression Bumper Cylinder Head Asm Upper Mount Pressure Valve Shaft Valve Screw Piston / Wear Band / Top-Out & Bottom-Out Washers 5.32 RepairPro Service Manual...

  • Page 142: Rear Shock Exploded View

    BODY / STEERING / SUSPENSION REAR SHOCK EXPLODED VIEW RydeFX™ REAR SHOCK (Compression Adjustable) Ref. Description Ref. Description Bushing Sleeve Spring Retainer Nut IFP O-Ring Compression Bumper Cylinder Head Asm Upper Mount Pressure Valve Shaft Valve Screw Piston / Wear Band / Top-Out & Bottom-Out Washers 5.33...

  • Page 143: Ryde Fx™ Shock Service

    BODY / STEERING / SUSPENSION RYDE FX™ SHOCK SERVICE Changing oil on RydeFX™ Shocks is recommended annually and should NOT be performed during end of season storage preparation. Shock Specification Chart Shown below is an example of how valving stacks are arranged. For competition use, shocks should be disassembled and serviced more frequently.

  • Page 144: Rydefx™ Shock Rebuild Procedure

    BODY / STEERING / SUSPENSION RydeFX™ Shock Rebuild Procedure NOTE: Before unscrewing pre-load springs, measure the compressed length of the installed Required Tools spring and mark position for reinstallation. • RydeFX Gas Charge Tool (Inflation Needle) CAUTION • RydeFX I.F.P Extraction / Locator Tool When removing the spring from a shock that •...
  • Page 145 BODY / STEERING / SUSPENSION Remove the small button head screw from the pressure Remove the pressure valve assembly from the lower end valve assembly. mount. Account for an O-ring. With an adjustable wrench, loosen and remove cylinder Using a slotted screwdriver, loosen the pressure valve head assembly.
  • Page 146 BODY / STEERING / SUSPENSION 11. Clean the inside of the shock body using clean parts- ASSEMBLY cleaning solvent and blow dry using compressed air. Place the piston rod upper mount into the vise. 12. Place the shock piston rod upper mount in bench vise, begin Reassemble damper rod assembly in the reverse order of piston and valve removal.
  • Page 147 NOTE: After filling the shock body with oil, allow a couple of minutes for all air bubbles to rise to the top. Polaris Gas Shock Oil - P/N 2870995 Using the tool as a handle, push the floating piston down With the cylinder head assembly pushed down against the into the shock body, being careful not to damage I.F.P wear...
  • Page 148 BODY / STEERING / SUSPENSION NOTE: During installation, some shock oil will 13. Using a flat head screw driver, turn the compression overflow. Wrap a shop cloth around shock body to adjusting cam clockwise to ensure there is positive catch possible oil overflow. engagement of the internal adjusting rod with the surface of the adjusting cam.
  • Page 149 BODY / STEERING / SUSPENSION NOTES 5.40 RepairPro Service Manual...
  • Page 150 BRAKES CHAPTER 6 BRAKES BRAKE SPECIFICATIONS ..........6.2 GENERAL SPECIFICATIONS .

  • Page 151: General Specifications

    BRAKES BRAKE SPECIFICATIONS General Specifications FRONT BRAKE CALIPER Item Standard Service Limit Brake Pad Thickness .298″ / 7.6 mm .180″ / 4.6 mm Brake Disc Thickness .158” / 4.013 mm .140″ / 3.556 mm Brake Disc Thickness Variance – .002″ / .051 mm Between Measurements Brake Disc Runout –...

  • Page 152: Brake Caliper Exploded Views

    BRAKES BRAKE CALIPER EXPLODED VIEWS Rear Brake Caliper Assembly 16-18 ft.lbs. (22-24 Nm) Apply Polaris DOT 3 or DOT 4 brake fluid to component. 33 ft.lbs. (45 Nm) 27 in lbs. (3.1 Nm) A. Anvil Bolts B. Bleed Screws C. Washers D.

  • Page 153: Brake System Overview

    BRAKES BRAKE SYSTEM OVERVIEW Front Brake System - Exploded View A. Master Cylinder B. Brake Line C. Mechanical Brake Switch D. Wheel Hub E. Banjo Bolt & Washers F. Caliper G. Caliper Mount Bolt 15 ft. lbs. (20 Nm) 85 in. lbs. (9.6 Nm) 18 ft.

  • Page 154: Rear Brake System - Exploded View

    BRAKES Rear Brake System - Exploded View 18 ft. lbs. (24 Nm) 15 ft. lbs. (20 Nm) 15 ft. lbs. (20 Nm) A. Caliper B. Sealing Washer C. Banjo Bolt D. Brake Line E. Clevis Pin F. Master Cylinder Asm. G.

  • Page 155: Service Notes

    BRAKES Service Notes Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

  • Page 156: Hydraulic System Operation

    Make sure the vent is open and allowed to function. If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake failure. When servicing Polaris ATV brake systems use only Polaris DOT 3 or DOT 4 Approved High Temperature Brake Fluid. WARNING Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws.

  • Page 157: Brake Fluid Replacement And Bleeding Procedure

    Add brake fluid to the upper level mark on reservoir. Brake fluid will damage finished surfaces. Do not allow brake fluid to come in contact Polaris DOT 3 or DOT 4 Brake Fluid with finished surfaces. NOTE: This procedure should be used to change Begin bleeding procedure with either front caliper.
  • Page 158 Add to MAX level inside reservoir. Sight glass must look dark, if sight glass is clear, fluid level is too low 13. Install diaphragm, cover, and screws. Torque the screws to 11 in.lbs. (1.2 Nm). Polaris DOT 3 or DOT 4 Brake Fluid...

  • Page 159: Master Cylinder

    BRAKES Install a box end wrench on the upper rear caliper bleeder 11. Field test machine at low speed before putting into service. screw. Attach a clean, clear hose to fitting and place the Check for proper braking action and lever reserve. With other end in a clean container.

  • Page 160: Installation

    BRAKES Installation Remove master cylinder from handlebars. Install master cylinder on handlebars. Torque mounting bolts to 85 in. lbs. (9.6 Nm). Torque the top bolt first. Master Cylinder 15 ft. lbs. (20 Nm) Front Brake Line 85 in. lbs. (9.6 Nm) Banjo Bolt 15 ft.

  • Page 161: Front Caliper Service

    Loosen pad adjuster screw 2-3 turns. Remove the upper and lower caliper mounting bolts and remove the caliper assembly from the caliper mount. Polaris DOT 3 or DOT 4 Brake Fluid Follow bleeding procedure. Check all connections for leaks and repair if necessary.

  • Page 162: Caliper Inspection

    BRAKES Caliper Inspection Remove mounting bracket, pin assembly and dust boot. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Remove dust seal and piston seal. Caliper Piston Bore I.D.: Std:.

  • Page 163: Caliper Reassembly

    Caliper Installation Install caliper and torque mounting bolts. Coat piston with clean Polaris DOT 3 or DOT 4 Brake Fluid (C). Install piston (D) with a twisting motion while pushing 18 ft. lbs inward. Piston should slide in and out of bore smoothly, 15 ft.lbs.

  • Page 164: Front Brake Pads

    BRAKES FRONT BRAKE PADS Push mounting bracket inward and slip outer brake pad past edge. Remove inner pad. Pad Removal Elevate and support front of ATV. CAUTION Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.

  • Page 165: Pad Assembly

    18 ft. lbs Lubricate mounting bracket pins with a light film of (24 Nm) Polaris Premium All Season Grease (PN 2871423), and install rubber dust boots. Slowly pump the brake lever until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.

  • Page 166: Front Brake Disc

    BRAKES FRONT BRAKE DISC Brake Disc Runout Disc Inspection Service Limit .010” (.254 mm) Visually inspect the brake disc for nicks, scratches, or damage. Disc Removal / Replacement Measure the disc thickness at 8 different points around the pad contact surface using a 0–1” micrometer. Replace disc Apply heat to the hub in the area of the brake disc if worn beyond service limit.

  • Page 167: Rear Caliper Service

    BRAKES REAR CALIPER SERVICE Remove the caliper slide bolts (B), mounting bracket (C), and brake pads (D). Caliper Removal Clean caliper area before removal. Using a flare nut wrench, remove the brake line (A). Place a container to catch brake fluid draining from brake line. Remove the outside dust boot (E).

  • Page 168: Caliper Inspection

    BRAKES Remove the caliper body bolts (G). Pull the caliper bodies Inspect piston for nicks, scratches, wear or damage. apart (if necessary). Replace if damaged or worn. Inspect Piston Clean the caliper body, piston, and retaining bracket with Inspect the brake disc and pads as outlined for brake pad brake cleaner or alcohol.

  • Page 169: Rear Brake Pad

    BRAKES Coat piston and inside of caliper body with clean DOT 3 REAR BRAKE PAD or DOT 4 Brake Fluid. Install piston with a twisting motion while pushing inward. Piston should slide in and out of bore Pad Removal smoothly, with light resistance. NOTE: Be sure that the O- Loosen both bolts and remove the rear brake mount bolt.

  • Page 170: Pad Installation

    BRAKES With pads installed, push caliper piston into caliper bore Measure the thickness of the pad material. Replace pads if (A) slowly using a C–clamp (B) or locking pliers. worn beyond the service limit. NOTE: Brake fluid will forced through compensating port into...

  • Page 171: Rear Brake Disc

    BRAKES Torque the caliper slide bolts to 33 ft.lbs. (45 Nm). NOTE: BRAKE BURNISHING: It is recommended that a burnishing procedure be performed after installation of new brake pads to extend service life 33 ft.-lb. and reduce noise. Start machine and slowly increase (45Nm) speed to 30 mph.

  • Page 172: Disc Removal

    BRAKES Disc Removal Remove brake disc mounting bolts (4). With ATV on the ground, loosen wheel nuts and hub nuts. Safely lift and support the rear of the ATV under the main frame. Remove right rear wheel and hub. Remove rear caliper and secure out of the way. NOTE: Do not allow the caliper to hang by the brake line.

  • Page 173: Troubleshooting

    BRAKES TROUBLESHOOTING Brakes Squeal • Dirty/contaminated friction pads • Improper alignment • Worn disc • Worn disc splines • Glazed brake pads Poor Brake Performance • Air in system • Water in system (brake fluid contaminated) • Caliper/disc misaligned • Caliper dirty or damaged •...
  • Page 174 ELECTRICAL CHAPTER 7 ELECTRICAL GENERAL INFORMATION ..........7.2 SPECIAL TOOLS .

  • Page 175: General Information

    ELECTRICAL GENERAL INFORMATION Timing Check Procedure The ignition timing inspection hole is located in the starter Special Tools / magneto housing. Remove the check plug. NOTE: Do not allow the engine to warm up. The PART NUMBER TOOL DESCRIPTION timing may retard approximately 2° when the engine is warm.

  • Page 176: Lighting And Controls

    ELECTRICAL LIGHTING AND CONTROLS Apply dielectric grease to the light bulb socket before installing the new bulb. Install the replacement bulb into headlight housing and rotate firmly. Neutral / Reverse Position Indicator Switch Test NOTE: The bulb must be positioned so the harness installs into the lamp at the outer side.

  • Page 177: Headlight Adjustment

    ELECTRICAL Install the adjuster bracket onto the inboard pivot pin of the Loosen the pivot screw (1) and adjust the beam to the headlamp. desired position. Adjust for approximately 1/16” clearance between the bracket and the edge of the headlight. Tighten the mounting screws.

  • Page 178: Brake Light Switch Tests

    ELECTRICAL Brake Light Switch Tests Clutch Switch Test Foot Brake Switch Disconnect wire harness from switch. Disconnect wire harness from switch. Connect an ohmmeter across switch contacts. The circuit should have an open line or infinity reading. Connect an ohmmeter across switch contacts. The circuit 3.

  • Page 179: Tether Switch Test (Accessory Option)

    ELECTRICAL Tether Switch Test (Accessory Option) ETC Operation Test Disconnect wire harness from switch. Remove throttle block cover by carefully releasing all tabs around edge of cover. Place transmission in neutral and apply parking brake. Start engine and open throttle lever slightly until engine RPM is just above idle speed.

  • Page 180: Ignition System

    ELECTRICAL IGNITION SYSTEM Circuit Breakers The circuit breaker panel is located underneath the front cab. Ignition System Troubleshooting Access can be gained by removing the cover. Removal of front cab may be required for better access. No Spark, Weak or Intermittent Spark •...

  • Page 181: Flywheel Identification

    ELECTRICAL Flywheel Identification Flywheel Identification Stamp Location The flywheel can be identified by the casting marks in location A. Refer to “I.D.” location in chart below. Engine Application Type Stamp Comment I.D. Stamp External IJ09 DC / CDI K1805 ES50PL Trigger Ignition DC / CDI Ignition...

  • Page 182: Ignition System Testing

    ELECTRICAL Ignition System Testing Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting. The resistance values are also given on the specification pages.

  • Page 183: Components Of Dc / Cdi Ignition

    ELECTRICAL Components of DC / CDI Ignition Note: DC/CDI components are not compatible with any other type of ignition. Refer To Wiring Diagrams For Specified Stator Coil Resistance Primary Resistance Ω High Tension Lead Meter Ignition Kill Wire .3 Ω (Black) 12 Volt DC Supply Wire...

  • Page 184: Cooling System

    ELECTRICAL COOLING SYSTEM Coolant Temperature Sensor Test (Hot Light) With the ignition switch (and engine stop switch) “ON”, power Fan Control Circuit Operation / Testing is delivered to the hot light via the Red / White wire. The Blue / White wire (ground) out of the light socket is The fan switch is located on the radiator.

  • Page 185: Coolant Fan Control Switch Operation Test

    ELECTRICAL Coolant Fan Control Switch Operation Test During start-up, the amperage should peak then decline rapidly. If the motor continues to draw more amperage than Place switch in a liquid bath and submerse it to the base of the fan circuit breaker rating during start-up, replace the the threads.

  • Page 186: Charging System "Break Even" Test

    ELECTRICAL Charging System “Break Even” Test Alternator Tests (Charging System) Three tests can be performed using a multimeter to determine CAUTION the condition of the stator (alternator). TEST 1: Resistance Value of Each Stator Leg Do not allow the battery cables to become Measure the resistance value of each of the three stator disconnected with the engine running.

  • Page 187: Charging System Testing Flow Chart

    ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are suspected, proceed with the following system check. Remove the battery and properly ser- Using a multitester set on D.C. volts, mea- vice. Reinstall the fully charged battery sure the battery open circuit voltage (See or a fully charged shop battery.

  • Page 188: Battery Service

    ELECTRICAL BATTERY SERVICE Battery Inspection / Removal The battery is located under the front cab at the front of the ATV. Battery Maintenance Removal of the front cab assembly is required to access the battery. Refer to Chapter 5 for front cab removal. WARNING Battery electrolyte is poisonous.

  • Page 189: Battery Terminals / Bolts

    ELECTRICAL Battery Terminals / Bolts Load Test Use Polaris corrosion resistant Dielectric Grease (PN 2871329) CAUTION on battery bolts. Battery Testing To prevent shock or component damage, remove spark plug high tension leads and Whenever a service complaint is related to either the starting connect securely to engine ground or charging systems, the battery should be checked first.

  • Page 190: Charging Procedure

    ELECTRICAL Charging Procedure STARTING SYSTEM NOTE: Remote charging terminals have been Starter System Troubleshooting provided to allow for battery charging without removal of the front cab. Starter Motor Does Not Turn Attach the Positive battery charging cable to the Red •...

  • Page 191: Clutch Switch Test

    ELECTRICAL Clutch Switch Test Starter Motor Disassembly Refer to “Clutch Switch Test” under the “Lighting and Use only electrical contact cleaner to clean starter motor parts. Controls” section of this chapter. Problems with the clutch Some solvents may leave a residue or damage internal parts and switch will cause the starter circuit to not operate.

  • Page 192: Brush Inspection / Replacement

    ELECTRICAL Brush Inspection / Replacement Inspect surface of commutator for wear or discoloration. See Steps 3–6 of armature testing on Page 7.20. Install a new carbon brush assembly in the brush housing. Brush Set NOTE: Be sure that the terminal bolt insulating washer is properly seated in the housing, and the tab on the brush plate engages the notch in the brush plate housing.

  • Page 193: Starter Reassembly

    ELECTRICAL Using a digital multitester, measure the resistance between Install O–Ring on other end of field magnet casing. Make each of the commutator segments. The reading should be sure it is in good condition and not twisted on the case. .3 ohms or less.

  • Page 194: Starter System Testing Flow Chart

    ELECTRICAL Starter System Testing Flow Chart Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- Remove battery and properly service.
  • Page 195 ELECTRICAL NOTES 7.22 RepairPro Service Manual...
  • Page 196 Brake Pads, Front ......6.15 Brake Pads, Rear ....... 6.20 A-Arm Replacement .
  • Page 197 Current Draw ........7.12 Fuel Tank Assembly, Exploded View ....4.3 CV Joint, Boot Replacement .
  • Page 198 Oil Pump Priming Procedure ..... 2.16 Specification, Drive Chain Wear Limit ....2.20 Specification, Float Height .
  • Page 199 Steering Knuckle, Removal and Installation ...5.8 Steering, Alignment ......2.24 Steering, Toe Alignment .
  • Page 200 WIRE DIAGRAM OUTLAW 500...
  • Page 201 WIRE DIAGRAM OUTLAW 500 RepairPro Service Manual...
  • Page 202 WIRE DIAGRAM OUTLAW 500...

This manual is also suitable for:

Outlaw 500 2006Outlaw 500 2007

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