Polaris Outlaw 500, Service Manual

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1.5
GENERAL INFORMATION
1
2006 - 2007 OUTLAW 500
MODEL NUMBER: A06(07)GP50AA,AB
ENGINE MODEL: ES500PLE041
JETTING CHART
Engine
Platform Fuji DOHC 4 stroke
Engine Model Number ES500PLE041
Engine Displacement 499cc
Number of Cylinders 1
Bore & Stroke (mm) 99.2 x 64.6 mm
Compression Ratio 10.8:1
Compression Pressure 130 psi
Engine Idle Speed 1600 Rpm
Cooling System Liquid
Thermostat Opening Temperature 160°F (71°C)
Overheat Warning High Temp Light
Lubrication Pressurized Dry Sump
Oil Requirements PS-4 Synthetic
Exhaust System 2 to 1 canister style
Carburetion
Carburetor model Mikuni BSR 42mm
Main Jet 145
Pilot Jet 37.5
Jet Needle 6GL68-40-2
Needle Jet O-0
Pilot Screw 2.5 Turns Out (Reference Only)
Float Height 13 mm (0.51")
Fuel Delivery Fuel Pump
Fuel Requirement 87 Octane (minimum)
Electrical
Alternator Output 200 w @ 3000 RPM
Voltage Regulator 3-Phase
Lights : Main Headlights Dual Beam 35 watts / 35 watts
Tail LED
Brake 26.9 watts
Neutral / Hot / Reverse 1 watt (ea.)
Ignition System DC/CDI Ignition
RPM Limit 9100 ± 100 / Reverse 5000 ± 100
Ignition Timing 30
o
+ 3
o
BTDC @ 3500 RPM
Spark plug / Gap NGK DCPR8E/ .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 speed
Main Sprocket - # Tooth 14
Rear Sprocket - # Tooth 38
Gear Ratio : 1st
2nd
3rd
4th
5th
Rev
2.43
1.61
1.29
1.09
0.92
2.07
Chain Size / Deflection 520 O-ring / 1/4-3/8” (6-8mm)
Clutch Type Wet Multi Plate
Clutch Lever Freeplay 1/8” – 3/16” / 3.1 – 4.7 mm
Steering / Suspension
Front Suspension
Style / Shock
Dual A-arm / RydeFX
™
Shock
Front Travel 10 in. / 25.4 cm
Rear Suspension
Style / Shock Independent A-Arm / RydeFX
™
Compression Adjustable Shock
Rear Travel 11 in. / 27.94 cm
Ground Clearance 11.5 in. / 29 cm
Shock Preload Adjustment
Front and Rear Threaded shock adjustment
with Spanner Wrench
Turning Radius 67 in. / 170 cm
Toe Out 0 - 1/16 in / .0 - .159 mm
Wheels / Brakes
Front
Wheel Size / Offset / Bolt Pattern
10x5 / 28.3mm - 4/156
Rear
Wheel Size / Offset / Bolt Pattern
9x8 / 58.8mm - 4/110
Front Tire
Make / Model / Size
Dunlop / Radial / 21x7-10
Rear Tire
Make / Model / Size
Dunlop / Radial / 20x10-9
Recommended Air Pressure
F / R 5 psi Front
5 psi Rear
Brake - Front Hydraulic Disc
Brake - Rear Hydraulic Disc
Altitude
AMBIENT TEMPERATURE
Below 40
o
F
Below 5
o
C
+40
o
F + Above
+5
o
C + Above
Meters
(Feet)
0-1800
(0-6000)
150 145
above 1800
(above 6000)
142.5 137.5