Polaris Outlaw 500 Page 153 Service Manual Download

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6.4

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.

18 ft. lbs.

85 in. lbs.
(9.6 Nm)

(24 Nm)

(20 Nm)

15 ft. lbs.

(20 Nm)

RepairPro Service Manual

Summary of Contents for Outlaw 500

Page 1: ...Fix it like a Pro...

Page 2: ...1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEM 5 BODY STEERING SUSPENSION 6 BRAKES 7 ELECTRICAL 8 WIRE DIAGRAMS...

Page 3: ......

Page 4: ...SERIAL NUMBER LOCATION 1 2 VEHICLE INFORMATION 1 2 PAINT CODES 1 2 REPLACEMENT KEYS 1 2 PUBLICATION NUMBERS 1 3 STANDARD TORQUE SPECIFICATIONS 1 3 SPECIFICATIONS 1 4 2006 2007 OUTLAW 500 1 5 SPECIAL...

Page 5: ...t keys can be made from the original key To identify which series the key is take the first two digits on the original key and refer to the chart to the right for the proper part number Should both ke...

Page 6: ...cifications 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...

Page 7: ...ion 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 130 cm Ground Clearance 11 5 in 29 cm Dry Weight 439 lbs 199 kg Gross Vehicle Wei...

Page 8: ...E 035 in 0 9 mm Battery Model Amp Hr Maintenance Free 9 Amp Hr Circuit Breakers Amps Main 15 Fan 10 Ignition 5 Starting Electric Standard Instrument Cluster N A Drivetrain Transmission Type Manual 5 s...

Page 9: ...upport Block 3 2872105 Water Pump Mechanical Seal Puller 3 PA 45958 Cam Chain Tensioner Assembly Tool 3 PA 46076 MAG End Crankshaft Nut Remover Installer 3 PA 46077 MAG End Crankshaft Installer 3 2871...

Page 10: ...ial tools when servicing any Polaris product Standard Tools and Engine Tools PU 45432 Caliper or A Basic Caliper Basic Micrometer PA 46502 Valve Spring Compressor PA 46087 Crankcase Separator PA 46075...

Page 11: ...OZ 2200634 Valve Seat Reconditioning Kit 2870459 Dial Indicator PV 35667 A Cylinder Leak down Tester 2872105 Water Pump Seal Puller 2871283 Crank Water Pump Seal Install Kit Suspension Tools PS 45261...

Page 12: ...7 Current Clamp 2870836 Battery Hydrometer 8712500 PV 39951 A Tachometer Tachometer Electrical Tools 2870630 Timing Light 2871745 Static Timing Light Harness 2460761 Hall Sensor Probe Harness PV 39991...

Page 13: ...449 61 64 9531 31 32 9688 25 mm 9843 63 64 9844 1 1 0 Thread Size Drill Size Thread Size Drill Size 0 80 3 64 1 2 13 27 64 1 64 53 1 2 20 29 64 1 72 53 9 16 12 31 64 2 56 51 9 16 18 33 64 2 64 50 5 8...

Page 14: ...nches cu in x 16 387 Cubic centimeters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Li...

Page 15: ...al direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm2 Kilograms per square centimeter kg m Kilogram meters Kilo...

Page 16: ...E INSPECTION 2 12 THROTTLE CABLE ELECTRONIC THROTTLE CONTROL ETC ADJUSTMENT 2 13 CHOKE ADJUSTMENT 2 13 AIR FILTER AND PRE FILTER SERVICE 2 13 AIR BOX DRAIN TUBE 2 14 CRANKCASE BREATHER FILTER INSPECTI...

Page 17: ...NTROLS 2 25 WHEEL ALIGNMENT 2 25 STEERING INSPECTION TIE ROD ENDS AND HUBS 2 26 TOE ALIGNMENT ADJUSTMENT 2 27 CAMBER AND CASTER 2 27 SUSPENSION SPRING PRELOAD ADJUSTMENT 2 27 REAR SHOCK COMPRESSION AD...

Page 18: ...diately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key The following symbols denote...

Page 19: ...t clean often E Air Box Sediment Tube Pre Ride Drain deposits when visible Coolant Pre Ride Check level daily change coolant every 2 years Head Lamp Tail Lamp Pre Ride Check operation apply dielectric...

Page 20: ...box 20 H Monthly 200 320 Inspect replace if necessary Valve Lash 50 H Check clearance Re shim only if out of specification General Lubrication 50 H 3M 500 800 Lubricate all grease fittings pivots cab...

Page 21: ...teering Post A 50 H 3 M 500 800 Inspect tighten fasteners grease after washing ATV or driving in water Front A arms B 50 H 3 M 500 800 Inspect tighten fasteners grease also after washing ATV or drivin...

Page 22: ...essure test system annually Radiator 100 H 12M 1000 1600 Inspect clean external surfaces change coolant every 2 years Cooling Hoses 100 H 12M 1000 1600 Inspect for leaks Engine Mounts 100 H 12M 1000 1...

Page 23: ...formation More often under severe conditions such as continuous operation in water mud or sand III Item Lube Rec Method Frequency 1 Engine Oil Transmission Polaris PS 4 Synthetic Check dipstick and ad...

Page 24: ...THREAD LOCKING AGENTS MISC 2870791 Fogging Oil 12 oz Aerosol 2871326 Premium Carbon Clean 12 oz 2870652 Fuel Stabilizer 16 oz 2870585 Loctite Primer N Aerosol 25 g 2870990 DOT 3 Brake Fluid 2872189 DO...

Page 25: ...steners in accordance with the maintenance schedule Check that all cotter pins are in place Refer to specific fastener torques listed in each chapter FUEL SYSTEM AND AIR INTAKE Fuel System Always stop...

Page 26: ...lve if problems are found 5 Reverse the procedures to install the fuel valve 6 Turn valve on start engine and inspect for leaks Carburetor Draining The carburetor float bowl should be drained periodic...

Page 27: ...Always check throttle cable freeplay after adjusting idle speed and adjust if necessary 1 Start engine and warm it up thoroughly 2 Adjust idle speed by turning the idle adjustment screw in clockwise...

Page 28: ...freeplay 6 Tighten lock nut securely and slide boot completely in place to ensure a water tight seal 7 Turn handlebars from left to right through the entire turning range If idle speed increases check...

Page 29: ...air filter into air box Install the air filter retaining screw 12 Reinstall the air box cover and secure the cover with the two clips Air Box Drain Tube Periodically check the air box drain tube locat...

Page 30: ...tank and crankcase drain plugs with clean shop towels 3 Run the engine for two to three minutes until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug 1 5...

Page 31: ...ld hear some air release If you do not the system has not primed Repeat the process if necessary Compression Test NOTE This engine has built in decompression components Compression readings will vary...

Page 32: ...omponents are warm If necessary blow debris from screen with compressed air 3 Inspect the screen for wear and damage Replace the arrestor is damage is found 4 Reinstall the arrestor and torque the bol...

Page 33: ...iator fitting may distort causing a restriction or leak Radiator hose clamp torque is 36 in lbs 4 Nm Radiator 1 Check radiator external air flow passages for restrictions or damage 2 Carefully straigh...

Page 34: ...the clutch cable to access the clutch adjustment screw B and lock ring C 3 Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease...

Page 35: ...mm gap between the side plate of the chain and the splice link clip See illustrations below Drive Chain Tension BREAK IN It is extremely important to maintain proper chain tension to ensure the best...

Page 36: ...the pivot mounting bolts to 30 ft lbs 41 Nm 4 Torque the chain adjusting bolt to 20 ft lbs 27 Nm Rear Driveshaft Boot Inspection Before Operating Inspect the boots before operating the vehicle If a b...

Page 37: ...y for 3 5 hours at a current equivalent of 1 10 of the battery s rated amp hour capacity i e 9 amp hr x 10 9 amp charging Do not use the alternator to charge a new bat tery Maintenance Free batteries...

Page 38: ...ry maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with fresh water after cleaning NOTE D...

Page 39: ...r a sharp outer electrode edge with no rounding or erosion 9 If needed clean spark plug with electrical contact cleaner or a glass bead spark plug cleaner only NOTE Wire brushes or coated abrasives sh...

Page 40: ...r procedure METHOD 1 USING A STRAIGHTEDGE OR STRING 1 Position the vehicle on a level surface NOTE Always measure toe alignment on a flat ground surface 2 Place the handlebars in a straight ahead posi...

Page 41: ...ng vehicle forward or backward Position chalk marks even with the hub axle centerline or the specified floor measurement 6 Again measure the distance between the marks and record Call this measurement...

Page 42: ...ngine 3 Elevate the front of the vehicle by placing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the dist...

Page 43: ...ter use 5 Remove the support stand and have a rider sit comfortably on the seat with hands on the handlebars 6 Place the transmission in neutral and slowly roll the machine forward and backward at lea...

Page 44: ...he brake system in good operating condition Service life of brake system components depends on operating conditions Inspect brakes in accordance with the maintenance schedule and before each ride Keep...

Page 45: ...leed the hydraulic auxiliary brake system in a conventional manner following the procedure outlined in the Brake Chapter WHEELS AND TIRES Wheels Inspect all wheels for runout or damage Check wheel nut...

Page 46: ...and tire wear On vehicles with flange wheel nuts make sure flat of nut goes onto wheel CAUTION Maintain proper tire pressure Refer to the warning tire pressure decal applied to the vehicle Tire Press...

Page 47: ...NOTES MAINTENANCE 2 32 RepairPro Service Manual...

Page 48: ...ON AND REASSEMBLY 3 14 CAMSHAFT REMOVAL 3 15 AUTOMATIC COMPRESSION RELEASE INSPECTION 3 15 CAMSHAFT INSPECTION 3 16 CYLINDER HEAD REMOVAL 3 16 CYLINDER AND PISTON REMOVAL 3 17 PISTON REMOVAL 3 17 PIST...

Page 49: ...TALLATION REAM 3 36 VALVE SEAT RECONDITIONING 3 37 VALVE INSPECTION 3 39 ES50PL ADJUSTING PAD SELECTION MATRIX 3 40 CYLINDER HEAD ASSEMBLY 3 41 CYLINDER HEAD INSTALLATION 3 42 CYLINDER SERVICE 3 42 CY...

Page 50: ...14mm 111 125 150 170 Nm Neutral Indicator Switch 5mm 2 2 3 7 3 5 Nm Oil Delivery Pipe 12mm 11 1 15 5 15 21 Nm Oil Drain Bolt Crankcase 14mm 14 17 19 23 Nm Oil Filter Cover Housing and Oil Pump Case 6m...

Page 51: ...Seat Contacting width Measure valve stem height In Std 1 5255 38 75 mm Limit 1 5425 39 18 mm Ex Std 1 5255 38 75 mm Limit 1 5377 39 06 mm Valve Guide Inner diameter 2362 2367 6 0 6 012 mm Protrusion a...

Page 52: ...on pin to pin bore clearance 0002 0004 001 0011 mm Degree of fit Piston Pin must be a push by hand fit at 68o F 20o C Piston Ring to ring groove clearance Top Ring Std 0012 0028 030 070 mm Limit 0059...

Page 53: ...OTE This engine has built in decompression components Compression readings will vary in proportion to cranking speed during the test Average compression measured is about 85 90 psi 400 RPM during a co...

Page 54: ...water in a 50 50 or 60 40 ratio depending on freeze protection required in your area IMPORTANT Using tap water in the cooling system will lead to a buildup of deposits which may restrict coolant flow...

Page 55: ...etor will not have to be disconnected from the throttle cable choke cable and fuel line for engine removal Insert a shop towel into the carburetor flange to prevent dirt from entering the intake of th...

Page 56: ...ring 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 r...

Page 57: ...nkshaft runout must be as close to zero as possible NOTE Maximum allowable runout is 0024 ES50PL Engine Lubrication Oil Type Polaris PS 4 Synthetic PN 2874414 Capacity Approximately 2 25 U S Quarts 2...

Page 58: ...ough a PTO side oil passage lubricating the crank bearings crank pin piston cylinder and connecting rod bearings A delivery pipe supplies oil to the top of the cylinder head and the transmission main...

Page 59: ...ipe Oil Shaft Transmission Main Shaft Transmission Counter Shaft Crankcase Cylinder Piston Connecting Rod Small End Large End Bearing Crank Pin Crankshaft Gears Gears Clutch Gears Ball Bearing Mag Sid...

Page 60: ...3 13 ENGINE 3 ES50PL Engine Exploded Views Crankshaft and Piston Cylinder Cylinder Head Valve Train Crankcase Transmission...

Page 61: ...soft face hammer and remove tensioner 7 For installation retract the plunger using the special tool and reverse the installation procedures using a new gasket Tighten bolts to specification Page 3 3...

Page 62: ...it while removing the chain from the cam gear Repeat this procedure for the other cam NOTE Do not allow cam chain to drop into the engine if no other disassembly is being performed 5 Use a device to...

Page 63: ...s NOTE Replace cylinder head if camshaft journal bore is damaged or worn excessively Cylinder Head Removal 1 Remove the cam shafts 2 Remove the two 8mm flange bolts A from cylinder head 3 Loosen each...

Page 64: ...Piston Support Block PN 2870390 5 Remove dowel pins from crankcase Piston Removal 1 Remove circlip Note piston directional aid that is pointing toward the left stator side of engine 2 Remove piston ci...

Page 65: ...or piston pin if out of tolerance 3 Measure piston ring to groove clearance by placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearan...

Page 66: ...fts on both ends and record Measure in two directions 90 apart to determine if components are out of round Replace if components are worn or damaged 5 Measure the ID of the bushing in the stator housi...

Page 67: ...tallation of flywheel and starter gears reverse the removal procedures When installing the flywheel apply engine oil to the crankshaft threads and torque the flywheel nut to 111 125 ft lbs 150 170 Nm...

Page 68: ...NOTE Replace clutch pack if measured thickness of friction material is less than 110 2 8mm The top plate has slightly different friction pads and should always be installed on top 7 To remove the clut...

Page 69: ...eplace if wear or damage is evident 4 Installation Reverse the procedures paying close attention to the orientation of the ratcher pawls F during installation as the surface must be flat when the pawl...

Page 70: ...p body are loose and may become lost Keep pins in a secure location 5 Replace any component that is found to be damaged or worn 6 Installation Reverse the procedures Use assembly lube or clean engine...

Page 71: ...ng rollers or damage Stretch chain tight on a flat surface and apply a 10 lb 4 53 kg load Measure length of a 20 pitch pin section of chain Replace if worn past service limit 3 Installation Reverse th...

Page 72: ...d visually and by feel Look for signs of discoloration scoring or galling Turn the inner race of each bearing The bearings should turn smoothly and quietly The outer race of each bearing should fit ti...

Page 73: ...ion removal 4 To reassemble reverse the procedures using the photos for reference Transmission Main Shaft Disassembly Assembly 1 Attach a bearing splitter to the reverse gear ONLY as shown DO NOT appl...

Page 74: ...educe binding during assembly NOTE Do not to allow transmission parts to fall from their assemblies during installation Parts that are out of alignment will cause improper casehalf mating resulting in...

Page 75: ...shift drum 5 Insert and rotate the shift drum so the alignment pin is approximately at the 5 o clock position Insert the fork pins into their respective cam followers installing each fork shaft as the...

Page 76: ...ress the bearing into the crankcase at the outer edges with an appropriate driver Insert the bearing retainers and new screws which have a pre applied locking agent Torque the screws to 8 1 9 6 ft lbs...

Page 77: ...mplished with the stator side casehalve settled in a suitable fixture that allows it to lay flat This allows easier installation without parts falling out of position Make sure the oil gallery tube is...

Page 78: ...lways check piston ring installed gap before rings are installed on piston If the piston has been in service clean any accumulated carbon from the ring grooves and oil control ring holes 1 Place the o...

Page 79: ...tating the engine to avoid damage to the chain drive sprocket teeth or tensioner blade Cam Chain Installation NOTE The camshafts crankshaft sprocket and clutch basket must be removed to perform this p...

Page 80: ...E Failure to align marks in this fashion will cause valve to piston interference resulting in engine damage 6 Re check all cam timing marks to verify proper cam timing and install the cam tower Tighte...

Page 81: ...3 34 ENGINE Outlaw Cam Timing Exploded View RepairPro Service Manual...

Page 82: ...rvice limit replace the cylinder head Cylinder Head Disassembly 1 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 dam...

Page 83: ...the described conditions exist the valve seat must be reconditioned If the valve seat is cracked the cylinder head must be replaced NOTE Servicing the valve guides and valve seats requires special too...

Page 84: ...r and a nylon brush Rinse and dry with compressed air Apply clean engine oil to guides Valve Seat Reconditioning 1 Follow the manufacturers instructions provided with the Valve Seat Reconditioning Kit...

Page 85: ...act area is centered on the valve face measure seat width If the seat is too wide or uneven use both top and bottom cutters to narrow the seat If the seat is too narrow widen using the 45 cutter and r...

Page 86: ...ng wearordamage A 4 Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves cannot be re faced or end ground Valves must be replaced if worn bent or damaged 5 Measure...

Page 87: ...isting pad 4 Measure and confirm that valve clearance is within the standard values 5 If valve clearance is not within standard reverify step 1 and repeat procedures again Example Intake Valve clearan...

Page 88: ...w split keeper installation and prevent loss of spring tension Install split keepers with the gap even on both sides 7 Repeat procedure for remaining valves 8 When all valves are installed tap lightly...

Page 89: ...top of the cylinder for warp using a straight edge and feeler gauge 3 Inspect cylinder for wear scratches or damage 4 Inspect cylinder for taper and out of round with a telescoping gauge or a dial bo...

Page 90: ...hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines...

Page 91: ...CE Oil Seal Mechanical Seal Removal Engine Disassembled NOTE The water pump mechanical seal can be removed without removing the engine Refer to Water Pump Mechanical Seal Installation Replace the wate...

Page 92: ...tach the puller legs to the main puller body Figure 3 46 4 Ensure that the split between the puller legs are fully supported by the main body of the tool Figure 3 46 5 Tighten the hex socket screws on...

Page 93: ...OUBLESHOOTING Engine Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative restricted Tank vent plugged Carb starter circ...

Page 94: ...Excessive Smoke and Carbon Buildup Excessive piston to cylinder clearance Wet sumping Worn rings piston or cylinder Worn valve guides or seals Restricted breather Air filter dirty or contaminated Low...

Page 95: ...eather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Restricted oil tank vent Cooling System Overheating Low coolant level Air in cooling s...

Page 96: ...ERATION 4 5 PILOT IDLE AND SLOW SYSTEM 4 6 STARTER SYSTEM CHOKE OR ENRICHMENT 4 7 FLOAT SYSTEM 4 7 MAIN SYSTEM 4 8 PILOT SCREW 4 8 CARBURETOR DISASSEMBLY 4 9 CARBURETOR CLEANING 4 10 CARBURETOR INSPEC...

Page 97: ...8 Washer 23 Spring Idle Adjust 38 Screw 53 Filter 9 Jet Needle 24 O ring 39 Screw 54 Jet Pilot Air 2 1 3 10 O ring 25 Screw Adjust 40 Jet Pilot 55 Jet Pilot Air 1 110 11 Case 26 Pin Float 41 Jet Start...

Page 98: ...Vent Line Fuel Tank Fuel Valve Fuel Lines Impulse Line Fuel Pump Tank Cap In Line Filter FUEL FLOW Fuel Tank Vent Fuel Tank Fuel Screens Fuel Valve Filter in Pickup Fuel Pump Carburetor Engine Carbur...

Page 99: ...31543 145 3131524 40 3131544 147 5 3131525 42 5 3131545 152 5 3131526 47 5 3131546 155 3131527 50 3131547 157 5 3131528 52 5 3131548 160 3131529 55 3131549 162 5 3131530 57 5 3131550 165 3131531 60 31...

Page 100: ...ter of the vacuum slide dampens the slide movement and assists the return of the slide Carburetor Component Function System Main Components Main Function Main Affect Float System Level Control Inlet P...

Page 101: ...the venturi and therefore the air velocity in the venturi is kept relatively constant This provides improved fuel atomization and optimum fuel air ratio Pilot Idle and Slow System This system supplies...

Page 102: ...starter outlet 6 in the main bore Float System Fuel enters the float chamber 3 by means of the inlet pipe and passage through a screen on the back of the inlet needle seat 4 and around the inlet need...

Page 103: ...e emulsified fuel must flow is determined ultimately by throttle position and vacuum slide height Pilot Screw The pilot system supplies fuel during engine operation with the throttle valve closed or s...

Page 104: ...Then the float and float pin can be removed 3 Remove inlet needle seat retaining screw along with plate and carefully remove needle seat NOTE Do not use a pliers to remove the seat or permanent damage...

Page 105: ...edle and needle jet to prevent a rich condition TIP A worn needle jet is difficult to spot To check slide a slightly larger new jet needle into the needle jet and hold it to a light source Light will...

Page 106: ...O ring during installation Turn the screw in until it lightly contacts the seat Then back it out the specified number of turns NOTE The final pilot idle mixture must be adjusted with the engine runnin...

Page 107: ...oat bowl Invert the carburetor and install a Mity Vac PN 2870975 to the fuel inlet fitting Apply 5 PSI pressure to inlet fitting The needle and seat should hold pressure indefinitely If not inspect ne...

Page 108: ...t inlet and outlet check valves for cracks warpage or damage Inspect the diaphragms for cracks holes or swelling 2 To clean the valves or pump body remove the set screw and washer Remove the valve and...

Page 109: ...k or damaged vacuum piston return spring Fouled spark plug Poor Idle Idle Too High Idle adjusted improperly idle mixture screw damaged Sticky vacuum slide Throttle cable sticking improperly adjusted r...

Page 110: ...SSEMBLY 5 12 HUB INSTALLATION 5 13 FRONT SUSPENSION EXPLODED VIEW 5 14 FRONT A ARM REPLACEMENT 5 15 A ARM REMOVAL AND INSPECTION 5 15 A ARM INSTALLATION 5 15 REAR SUSPENSION EXPLODED VIEW 5 16 REAR A...

Page 111: ...W 5 32 RYDE FX FRONT SHOCK 5 32 REAR SHOCK EXPLODED VIEW 5 33 RYDE FX REAR SHOCK COMPRESSION ADJUSTABLE 5 33 RYDE FX SHOCK SERVICE 5 34 SHOCK SPECIFICATION CHART 5 34 PISTON ORIENTATION 5 34 RYDE FX S...

Page 112: ...Steering Post Arm 33 ft lbs 45 Nm Centerlink Idler Arm 33 ft lbs 45 Nm REAR SUSPENSION Rear A Arm Attaching Bolts 33 ft lbs 45 Nm Rear Hub Nut 90 ft lbs 122 Nm Rear Hub Carrier Bolts 30 ft lbs 41 Nm U...

Page 113: ...t B Seat Release Latch C Rear Cab D Side Panel E Front Cover F Front Cab G Heel Pocket H Heel Support I Grab Bar J Fuel Tank Cover K Frame L Foot Peg M Rock Guard N Front Bumper O Rear Cab Support A B...

Page 114: ...owards the rear of the ATV to completely disengage the side panel locking tabs 4 Reverse the removal steps to reinstall the side panel Front Cab 1 Remove the 4 torx head screws and the 2 6mm bolts hol...

Page 115: ...3 screws A from the lower portion and remove the heel pocket 3 Reverse the removal steps to reinstall the heel pocket Rear Cab 1 Remove the 2 bolts from the lower portion of the rear cab on each side...

Page 116: ...Steering Bushings D Steering Post E Zerk Fitting F Cotter Pin G Tie Rod Assembly H Sealed Ball Bearing I Ball Bearings J Foam Spacer K Tube Spacer L Steering Knuckle A B D E C F G H I J K L M Centerl...

Page 117: ...allation 1 Before installation check the condition of the ball joints Joints should move freely and have no axial play 2 Place the upper and lower A arms into the steering hub 3 Install the castle nut...

Page 118: ...all joint into place until the ball joint is properly installed 2 After the new ball joint is installed into the A arm install a NEW retaining ring Upon A arm installation onto the steering hub instal...

Page 119: ...er 5 2 Seal 6 2 Bearing Ball Sealed 7 2 Hub Wheel Front Indy Red 8 8 Stud 9 2 Spacer Tapered 10 2 Bearing Ball 11 2 Seal 12 2 Disc Brake 13 2 Spacer Inner 14 8 Bolt 15 2 Rim Front 16 2 Valve Rim 17 8...

Page 120: ...ine 5 Remove outer brake disc guard cotter pin front spindle nut and washer 6 Remove the outer spacer from the spindle Inspect outer spacer for wear replace if needed 7 Remove the hub from the spindle...

Page 121: ...amage Measure the tapered spacer for wear replace as needed Hub Assembly 1 Drive or press one new bearing into hub using a bearing driver 2 Coat bearing spacer with grease and install into hub Drive o...

Page 122: ...n Tighten nut slightly if necessary to align cotter pin holes 6 Bend both ends of cotter pin around end of spindle in different directions 7 Rotate hub It should rotate smoothly without binding rough...

Page 123: ...hine A B C C D D E F G H I J J L L K M A B I Install with A Springs B IFP Shock C Upper A Arm D Lower A Arm E A Arm Shaft F Bushings G Bolt H Flange Nut I Steering Knuckle J Ball Joints K Cotter Pins...

Page 124: ...removed 6 Examine A arm shafts I Replace if worn Discard hardware A arm Installation 1 Insert A arm shaft I into the new A arm D F 2 Install new A arm assembly onto vehicle frame upper and lower Torq...

Page 125: ...r Assembly B Torsion Bar Assembly C Upper A Arm D Lower A Arm E Guard F Bushings G Bolt H Flange Nut I Needle Bearing J Bearing Seals E D I F C F I I J J J 33 ft lbs 45 Nm 30 ft lbs 41 Nm 30 ft lbs 41...

Page 126: ...A arm tube and pry the hub carrier up and away from the A arm 5 Remove bolt C on the upper A arm tube and pry the hub carrier down and away from the A arm 6 Remove remaining bolts D from A arms and r...

Page 127: ...ng in the bore Press only on the outside diameter of the bearing Verify that an equal amount of space remains on each side to allow for seal installation NOTE Apply grease to the inside of the needle...

Page 128: ...ded View A CV Boot Retaining Ring B Inner CV Boot C Sprocket Hub D Bearing 2 E Rear Axle Housing F O Ring G Rear Brake Disc Hub H Brake Hub Retaining Ring A B C D E F H G I D A B CV Ball Cage Assembly...

Page 129: ...ke line damage may result 7 Remove both upper carrier bolts and secure upper a arms out of the way 8 Tilt each hub carrier outward while pulling rear CV shaft end from carrier assembly 9 Remove brake...

Page 130: ...r boots by pulling outward on boot A blunt prying tool may be required to break the sealing area NOTE Inner CV boots are sealed to housing Use caution during removal Boot damage may result 6 Using a f...

Page 131: ...ase 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 rol...

Page 132: ...itable holding fixture press or tap the carrier bearings into the housing NOTE Do not reuse the bearings if removed 2 Apply sealant to the sprocket hub splines before assembly 3 Using Special Tool PN...

Page 133: ...plunging joint has been centered properly Tighten boot clamps using boot clamp pliers Installation 1 Reverse the steps described in the Removal Disassembly procedure 2 Attach the rear housing mounting...

Page 134: ...bolt Carrier Disassembly Inspection 1 Remove outer snap ring 2 From the back side tap on the outer bearing race with a drift punch in the reliefs as shown NOTE Drive bearing out evenly by tapping on o...

Page 135: ...the shaft inside the bearing If replacement is required press the bearings out from opposite sides using a drift punch or other suitable tool Carrier Assembly 1 Assemble and install the upper A arm b...

Page 136: ...arrier until top aligns with upper control arm Install and torque upper control arm bolt and torque to specification Torque lower control arm bolts to specification Apply grease to zerk 5 Pull drive s...

Page 137: ...Remove clamps from rubber boot s using the CV Boot Clamp Pliers PN 8700226 A 2 Photo below is shown without shaft for clarity Wipe grease away from recess in CV joint inner hub and locate snap ring 3...

Page 138: ...on 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 Use the recommended amount of grease...

Page 139: ...to use only the Constant Velocity Joint grease supplied with boot service kit IF CV JOINT WAS CLEANED add the required amount of grease to the joint in addition to the grease pack supplied with boot k...

Page 140: ...area where the decal is to be applied until the surface appears slightly glossy This should occur after just a few seconds of flame treating Do not hold the torch too close to the surface 2 3 inches f...

Page 141: ...on Ref Description 1 Bushing 8 Nut 2 Sleeve 9 IFP 3 Spring Retainer Nut 10 IFP O Ring 4 Compression Bumper 11 Cylinder Head Asm 5 Upper Mount 12 Pressure Valve 6 Shaft 13 Valve Screw 7 Piston Wear Ban...

Page 142: ...n Adjustable Ref Description Ref Description 1 Bushing 8 Nut 2 Sleeve 9 IFP 3 Spring Retainer Nut 10 IFP O Ring 4 Compression Bumper 11 Cylinder Head Asm 5 Upper Mount 12 Pressure Valve 6 Shaft 13 Val...

Page 143: ...ide with the greater number of slots should face the IFP nut end of the shaft Changing oil on RydeFX Shocks is recommended annually and should NOT be performed during end of season storage preparation...

Page 144: ...k mount eyelet Secure the lower mount of the shock in a vise The use of soft jaws is recommend to prevent damage or marks to the shock WARNING Before servicing a gas shock it is important that all the...

Page 145: ...iscard old oil into an approved storage container and dispose appropriately Never reuse damper oil during shock rebuild 10 Using the I F P extraction tool thread the tool into the I F P and pull upwar...

Page 146: ...racking or being missing Should any of these items be in question replacement is recommended ASSEMBLY 1 Place the piston rod upper mount into the vise Reassemble damper rod assembly in the reverse ord...

Page 147: ...se to the pressure valve port counterbore through 360 where the pressure valve assembly O ring meets 7 Screw the pressure valve assembly into the valve port by hand with a slotted head screwdriver Tig...

Page 148: ...essurize the shock through the pressure valve with nitrogen gas to the specified pressure NOTE After being compressed the piston rod should fully extend from the shock body once the shock has been pre...

Page 149: ...NOTES BODY STEERING SUSPENSION 5 40 RepairPro Service Manual...

Page 150: ...10 INSTALLATION 6 11 FRONT CALIPER SERVICE 6 12 CALIPER REMOVAL AND DISASSEMBLY 6 12 CALIPER INSPECTION 6 13 CALIPER REASSEMBLY 6 14 CALIPER INSTALLATION 6 14 FRONT BRAKE PADS 6 15 PAD REMOVAL 6 15 PA...

Page 151: ...4 6 mm Brake Disc Thickness 158 4 013 mm 140 3 556 mm Brake Disc Thickness Variance Between Measurements 002 051 mm Brake Disc Runout 010 254 mm Master Cylinder I D Aux Rear 500 12 7 mm ITEM TORQUE ft...

Page 152: ...racket L Pad M Front Housing N Retaining Clips Apply Polaris DOT 3 or DOT 4 brake fluid to component A B C D E F G H I J K L M N 33 ft lbs 45 Nm 27 in lbs 3 1 Nm 16 18 ft lbs 22 24 Nm A Socket Set Scr...

Page 153: ...stem 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 A B B B C D E F G 15 ft lbs 18 ft lbs 85 in lbs 9 6 Nm 24 Nm...

Page 154: ...in F Master Cylinder Asm G Cotter Pin H Rear Brake Reservoir I Hose Clamp J Reservoir Hose K Brake Switch L Brake Switch Bracket M Switch Spring N Washer O Bushing A B C B C D E F G H I J K L M N O P...

Page 155: ...pad for worn spots allowing metal to metal contact See table below CAUTION Use only DOT 3 or DOT 4 brake fluid as an assembly aid for all procedures described in this chapter to prevent brake system c...

Page 156: ...within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is o...

Page 157: ...servoir 6 Begin bleeding procedure with either front caliper Install a box end wrench on the caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be...

Page 158: ...rake Caliper Bleeding 1 Clean rear brake fluid reservoir cover thoroughly 2 Remove the cap and diaphragm from the reservoir 3 If changing fluid remove old fluid from reservoir with a Mity Vac PN 28709...

Page 159: ...rk on reservoir 11 Field test machine at low speed before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3...

Page 160: ...master cylinder of air 2 Place new sealing washers on each side of banjo brake line Install the brake line into the master cylinder Torque the brake switch bolt to 15 ft lbs 20 Nm Master Cylinder Fro...

Page 161: ...wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 4 Loosen pad adjuster screw 2 3 turns 5 Remove the upper and lower caliper mounti...

Page 162: ...r nicks scratches or wear Measure bore size and compare to specifications Replace if damage is evident or if worn beyond service limit 2 Inspect piston for nicks scratches wear or damage Measure diame...

Page 163: ...mpress the mounting bracket and make sure the dust seals are fully seated Install the brake pads Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease...

Page 164: ...s with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove excess fluid from reservoir as requi...

Page 165: ...1 2 turn counterclockwise 6 Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap 7 Install wheels and torque wheel nuts NOTE Front Wheel Nut Torque Refer to To...

Page 166: ...l Replacement 1 Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent 2 Remove bolts and disc 3 Clean mating surface of disc and hub 4 Install disc on hub...

Page 167: ...id draining from brake line 3 Remove the caliper mounting bolts B and remove the caliper assembly from the caliper mount Caliper Disassembly 1 Remove the c clips A from the caliper sliding bolts 2 Rem...

Page 168: ...rooves in caliper body 2 Inspect piston for nicks scratches wear or damage Replace if damaged or worn 3 Inspect the brake disc and pads as outlined for brake pad replacement this section Caliper Assem...

Page 169: ...liper slide bolts E and c clips F 6 Torque the caliper slide bolts E to 33 ft lbs 45 Nm REAR BRAKE PAD Pad Removal 1 Loosen both bolts and remove the rear brake mount bolt Tip the caliper and re torqu...

Page 170: ...re the thickness of the pad material Replace pads if worn beyond the service limit Pad Installation 1 Install new pads A in caliper body Slide the caliper slide bolts B into the caliper and hand tight...

Page 171: ...machine Repeat this procedure 10 times allowing brakes to cool sufficiently after each run REAR BRAKE DISC Disc Inspection 1 Visually inspect disc for scoring scratches or gouges Replace the disc if a...

Page 172: ...er assembly 7 Remove brake disc mounting bolts 4 8 Lift and rotate disc slipping it over the hub assembly and off the driveshaft exiting the frame from the side Disc Replacement 1 Install disc slippin...

Page 173: ...d stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch Lever Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Cal...

Page 174: ...IGNITION 7 10 COOLING SYSTEM 7 11 FAN CONTROL CIRCUIT OPERATION TESTING 7 11 COOLANT TEMPERATURE SENSOR TEST HOT LIGHT 7 11 FAN CONTROL SWITCH BYPASS TEST 7 11 COOLANT FAN CONTROL SWITCH OPERATION TE...

Page 175: ...r reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply Ignition timing is non adjustab...

Page 176: ...the light bulb socket before installing the new bulb Install the replacement bulb into headlight housing and rotate firmly NOTE The bulb must be positioned so the harness installs into the lamp at th...

Page 177: ...at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on...

Page 178: ...ms resistance when the brake is applied with slight pressure Clutch Switch Test 1 Disconnect wire harness from switch 2 Connect an ohmmeter across switch contacts The circuit should have an open line...

Page 179: ...nical problem in the throttle mechanism cable tension is lost the switch contacts close connecting the CDI black wire to ground which prevents ignition spark This is the same as turning the key or eng...

Page 180: ...el loose or damaged Excessive crankshaft runout on magneto RH end should not exceed 005 Faulty CDI module Circuit Breakers The circuit breaker panel is located underneath the front cab Access can be g...

Page 181: ...rrent is supplied directly to the CDI unit from the battery At the CDI the supplied 12 volt DC current charges an internal capacitor to build up the initial ignition charge A small AC signal from the...

Page 182: ...meter The coil mount should have good continuity to ground on the engine 0 3 Disconnect and check the secondary coil Primary Side Primary wire tab to engine ground on coil mount or engine 3 to 5 Ohms...

Page 183: ...er to Page 7 8 for Flywheel identification One way starter clutch Starter Drive gear Meter 190 Pulse Coil Trigger Air Gap 016 030 4 75mm Reverse Signal Coil Located in stator Starter Solenoid CDI Box...

Page 184: ...emperature switch on the cylinder head In normal operating conditions the temperature switch is non conductive open If engine coolant reaches the specified temperature the switch becomes conductive co...

Page 185: ...ree to rotate 5 Turn ignition key and engine stop switch to RUN position Read the current draw on ammeter with fan running 6 During start up the amperage should peak then decline rapidly If the motor...

Page 186: ...ing a multimeter to determine the condition of the stator alternator TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2...

Page 187: ...ect the alternator wires Note Red wire must be connected to harness Battery voltage must be present on red wire terminal on harness side of voltage regulator connector Is it If all of the previous tes...

Page 188: ...ct holder strap 3 Disconnect battery negative black cable first followed by the positive red cables 4 Remove the battery 5 Clean battery cables and terminals with a stiff wire brush Corrosion can be r...

Page 189: ...age the starter and observe the battery voltage while cranking the engine Continue the test for 15 seconds During cranking the observed voltage should not drop below 9 5 volts If the beginning voltage...

Page 190: ...ons see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty kill...

Page 191: ...orroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on...

Page 192: ...ce of commutator for wear or discoloration See Steps 3 6 of armature testing on Page 7 20 6 Install a new carbon brush assembly in the brush housing NOTE Be sure that the terminal bolt insulating wash...

Page 193: ...lding it in place with a light film of grease 5 Install case sealing O Ring Make sure O Ring is in good condition and not twisted on the case Lubricate needle bearing and oil seal with a light film of...

Page 194: ...operation Replace the defective component s or wiring No Test starter solenoid coil by connecting an ohmmeter between the solenoid red wire and the solenoid mounting plate Resistance should be 3 4 Ch...

Page 195: ...NOTES ELECTRICAL 7 22 RepairPro Service Manual...

Page 196: ...6 16 Brake Pad Thickness Front 6 15 Brake Pad Thickness Rear 6 21 Brake Pads Front 6 15 Brake Pads Rear 6 20 Brake Pads Rear Installation 6 21 Brake Pads Rear Removal 6 20 Brake Pads Removal Front 6 1...

Page 197: ...11 Front Suspension Exploded View 5 14 Fuel Line Inspection 2 10 Fuel Pump Assembly 4 13 Fuel Pump Disassembly 4 13 Fuel Pump Tests 4 13 Fuel System Inspection 2 10 Fuel System Troubleshooting 4 13 Fu...

Page 198: ...eel Nut Torque 3 20 Specification Handle Bar Fastener Torque 2 25 Specification Hub Carrier Fastener Torque 5 25 5 27 Specification Hub Nut Torque 5 27 Specification Idle Speed RPM 2 12 Specification...

Page 199: ...27 Torque Patterns Engine 3 6 Torque Specifications Standard 1 3 Transmission Removal 3 26 Troubleshooting Brake Noise 6 6 Troubleshooting Brake System 6 24 Troubleshooting Cooling 3 48 Troubleshootin...

Page 200: ...8 1 WIRE DIAGRAM OUTLAW 500...

Page 201: ...8 2 WIRE DIAGRAM OUTLAW 500 RepairPro Service Manual...

Page 202: ...8 3 WIRE DIAGRAM OUTLAW 500...

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Polaris Outlaw 500, Service Manual

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