Polaris Outlaw 500, Service Manual, Page: 34 / 202

2.19
MAINTENANCE
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2. Fill reservoir to upper mark with Polaris Premium 60/40
Anti Freeze / Coolant (
PN 2871323 ) or a mixture of
antifreeze and distilled water as required for freeze
protection in your area.
3. Reinstall cap.
NOTE: If overheating is evident, allow system to
cool completely and check coolant level in the
radiator. Inspect for signs of trapped air in system.
Cooling System Pressure Test
See Chapter 3 for testing procedures.
Radiator Screen Removal
1. Remove the 4 screws retaining the radiator screen for
access to the radiator fins when cleaning.
FINAL DRIVE
Clutch Adjustment
1. Measure clutch lever freeplay between the perch and the
lever (A). This distance should be 1/8” – 3/16” (3.1 mm –
4.7 mm)
2. If adjustment is required, slide the clutch perch pivot boot
down 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 lever travel. Tighten the
lock ring.
4. Squeeze the lever fully and release. Slightly squeeze the
lever again until a slight resistance is felt. Measure the
freeplay again. If necessary, repeat the adjustment
procedure until proper freeplay is attained.
5. Replace the clutch perch pivot boot over the screw and lock
ring.
Reverse Lock-Out Lever Inspection and
Cable Adjustment
Check for smooth lever operation and ensure that the lever
returns freely without binding (1).
Adjust the reverse cable freeplay to .08”-.12” by adjusting the
cable jam nuts (2).
Sprocket Inspection
Inspect the sprocket for worn, broken or bent teeth.
To check for wear, pull upward on the chain at the area indicated
(arrow). Replace sprocket if chain movement exceeds 1/4”
(.6 cm).
A
B
C
CLUTCH LEVER FREEPLAY
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