Polaris Outlaw 500, Service Manual

Page: 35 / 202

2.20
MAINTENANCE
Drive Chain Inspection / Replacement
Inspect the drive chain for missing or damaged O–Rings, link
plates, or rollers. Do not wash the chain with a high pressure
washer, gasoline or solvents; do not use a wire brush to clean the
chain as damage to the O–Rings may occur. Clean chain with
hot soapy water and a soft bristled nylon brush.
Polaris ATV drive chains are equipped with O–ring sealed
permanently greased pins and rollers.The sprockets and outer
rollers require periodic lubrication. Lubricate the chain with
Polaris Chain Lubricant (
PN 2872073 ).
Never allow battery acid to contact the drive chain.
The chain must be replaced when it reaches 3% elongation.
1. Stretch the chain tightly in a straight line.
2. Measure the length of 21 pitches (pins) from pin center to
pin center, and compare to the specification. Replace the
chain if the length exceeds the wear limit.
3. When replacing or reinstalling drive chain, install the
closed end of the splice link clip as shown, with the closed
end leading in forward operation. There should be a
.003-
.005
″
(.076-.127 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 possible chain life. There is a chain
break–in period of approximately 100 miles or two (2) tanks of
fuel. During this time chain tension should be watched very
closely and loads to the chain should be kept light.
CHECKING CHAIN TENSION:
Check the amount of chain slack by moving the vehicle slightly
forward to remove slack at the top side of the chain. At the
center point of the top side of the chain there should be
1/4” - 3/
8” (6-9 mm) deflection .
NOTE: The chain has a press-on master link. A
chain tool must be used if it’s necessary to remove
the chain for service.
Drive Chain Wear Limit, 21 Pitch Length:
Std: 12.5
″
(32 cm)
Wear Limit: 12.875” (32.7 cm)
Proper Spacelink Clip Opening Position
.003 - .005
″
(.076- .127 mm)
Gap after installation
CAUTION
Never adjust or operate the vehicle with the rear drive
chain too loose or too tight. Severe damage to the
transmission and drive components can result.
Master Link
Do not press
plate in too far
If a gap is noticed between the outside edge
of the master link and plate, back the plate out
and close the gap.
RepairPro Service Manual