Polaris Outlaw 500, Service Manual

Page: 31 / 202

2.16
MAINTENANCE
14. Replace the gasket in the cover.
15. Lubricate the gasket on the new filter with a film of fresh
engine oil.
16. Reinstall the spring and install the new filter with the open
end facing outward.
17. Install the cover and torque the bolts to 72–78 in. lbs. (8–
9 Nm) .
NOTE: The long bolt must be placed in the forward
hole.
18. Remove the dipstick and fill the oil tank with 2.25 quarts
(1.9 l) of Polaris PS-4 Engine Oil ( PN 2874414 ).
19. Place gear selector in neutral and set parking brake.
20. Start the engine and let it idle for one to two minutes. Stop
the engine and inspect for leaks.
21. Re–check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
22. Dispose of used filter and oil properly.
Oil Pump Priming Procedure
NOTE: The oil pump priming procedure should be
performed as a safeguard against loss of pump
prime when repairing oil tank, lines or engine.
1. Clamp or pinch off vent line approximately 2
″
from oil
tank (P), between the end of oil tank vent fitting and the
vent line.
2. Run engine for 5-10 seconds at IDLE.
3. Shut off engine. Remove the vent line clamp. The oil pump
should now be properly primed and ready for field
operation.
NOTE: If the system is primed properly you should
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 in
proportion to cranking speed during the test.
Average compression (measured) is about 85-90 psi
@ 400 RPM during a compression test.
A cylinder leakdown test is the best indication of engine
condition. Follow manufacturer’s instructions to perform a
cylinder leakage test. (Never use high pressure leakage testers,
as crankshaft seals may dislodge and leak).
Exhaust Pipe / Spark Arrestor
Gasket
P
Cylinder Compression w / decompression
Standard: 85-90 PSI @ 400 RPM
Cylinder Leakdown
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)
WARNING
• Do not perform clean out immediately after
the engine has been run, as the exhaust
system becomes very hot. Serious burns
could result from contact with exhaust
components.
• To reduce fire hazard, make sure that there
are no combustible materials in the area when
purging the spark arrestor.
• Wear eye protection.
• Do not stand behind or in front of the vehicle
while purging the carbon from the spark
arrestor.
• Never run the engine in an enclosed area.
Exhaust contains poisonous carbon monoxide
gas.
• Do not go under the machine while it is
inclined. Set the hand brake and block the
wheels to prevent roll back.
Failure to follow these warnings could result in
serious personal injury or death.
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