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Polaris 2006-2007 Outlaw 500 Service Manual – PDF DOWNLOAD
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Polaris 2006-2007 Outlaw 500 Service Manual – PDF DOWNLOAD
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Description
Polaris 2006-2007 Outlaw 500 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Polaris 2006-2007 Outlaw 500 Service Manual – PDF DOWNLOAD
Language : English
Pages : 202
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Polaris 2006-2007 Outlaw 500 Service Manual – PDF DOWNLOAD
2006-2007 POLARIS OUTLAW 500 SERVICE MANUAL.............................. 1 Foreward............................................................. 0 Manual Safety Labels and Directions.................................. 0 Trademarks........................................................... 0 TABLE.................................................................... 2 GENERAL INFORMATION...................................................... 4 Vehicle Identification............................................... 5 Model Identification............................................. 5 Engine Designation Number........................................ 5 VIN Identification............................................... 5 Unit Serial Number (VIN) Location................................ 5 Engine Serial Number Location.................................... 5 Vehicle Information.................................................. 5 Paint Codes...................................................... 5 Replacement Keys................................................. 5 Publication Numbers.............................................. 6 Standard Torque Specifications................................... 6 Specifications....................................................... 7 MODEL: 2007 OUTLAW 500........................................... 7 2007 OUTLAW 500.................................................. 8 Special Tools........................................................ 9 ‘Where Used’ Table............................................... 9 Special Tool Listing............................................. 10 Misc. Numbers / Charts............................................... 13 SAE Tap / Drill Sizes............................................ 13 Metric Tap / Drill Sizes......................................... 13 Decimal Equivalents.............................................. 13 Coversion Table.................................................. 14 Glossary of Terms................................................ 15 MAINTENANCE.............................................................. 16 Periodic Maintenance Chart........................................... 18 Periodic Maintenance Overview.................................... 18 Maintenance Chart Key............................................ 18 Pre-Ride Maintenance Interval.................................... 19 Recommended Pre-Ride Fluid Level Checks.......................... 19 0 - 50 Hour Maintenance Interval................................. 20 50 - 100 Hour Maintenance Interval............................... 21 100 - 300 Hour Maintenance Interval.............................. 22 Maintenance References........................................... 23 Lubricants and Service Products...................................... 24 Polaris Lubricants, Maintenance and Service Products............. 24 General Vehicle Inspection and Maintenance........................... 25 Pre-Ride / Daily Inspection...................................... 25 Frame, Nuts, Bolts, and Fasteners................................ 25 Fuel System and Air Intake........................................... 25 Fuel System...................................................... 25 Fuel Lines....................................................... 25 Vent Lines....................................................... 26 Fuel Valve....................................................... 26 Carburetor Draining.............................................. 26 Carburetor Pilot Screw Adjustment................................ 27 Idle Speed Adjustment............................................ 27 Throttle Inspection.............................................. 27 Throttle Cable / Electronic Throttle Control (ETC) Adjustment.... 28 Choke Adjustment................................................. 28 Air Filter and Pre-filter Service................................ 28 Air Box Drain Tube............................................... 29 Crankcase Breather Filter Inspection............................. 29 Engine and Transmission.............................................. 29 Engine Oil Level Check........................................... 29 Engine Oil and Filter Service.................................... 30 Oil Pump Priming Procedure....................................... 31 Compression Test................................................. 31 Exhaust Pipe / Spark Arrestor.................................... 31 Engine Mount Locations........................................... 32 Liquid Cooling System................................................ 32 Cooling System Overview.......................................... 32 Coolant Strength / Type.......................................... 33 Cooling System Hoses............................................. 33 Radiator......................................................... 33 Recovery Bottle Coolant Level Inspection......................... 33 Cooling System Pressure Test..................................... 34 Radiator Screen Removal.......................................... 34 Final Drive.......................................................... 34 Clutch Adjustment................................................ 34 Reverse Lock-Out Lever Inspection and Cable Adjustment........... 34 Sprocket Inspection.............................................. 34 Drive Chain Inspection / Replacement............................. 35 Drive Chain Tension.............................................. 35 Drive Chain Adjustment........................................... 36 Rear Driveshaft Boot Inspection.................................. 36 Rear Driveshaft Boot “Pressure Equalizing”....................... 37 Electrical and Ignition System....................................... 37 Battery Maintenance.............................................. 37 Battery Inspection / Removal..................................... 38 Battery Terminals / Bolts........................................ 38 Off Season Storage............................................... 38 Engine- To- Frame Ground......................................... 38 Charging Procedure............................................... 38 Spark Plug Inspection............................................ 39 Ignition Timing.................................................. 39 Steering and Suspension.............................................. 39 Steering......................................................... 39 Controls......................................................... 40 Wheel Alignment.................................................. 40 Steering Inspection / Tie Rod Ends and Hubs ..................... 41 Toe Alignment Adjustment......................................... 42 Camber and Caster................................................ 42 Suspension Spring Preload Adjustment............................. 42 Rear Shock Compression Adjustment................................ 44 Brake System......................................................... 44 Brake System Inspection.......................................... 44 Hose / Fitting Inspection........................................ 45 Brake Pad Inspection............................................. 45 Brake Testing.................................................... 45 Wheels and Tires..................................................... 45 Wheels........................................................... 45 Wheel, Hub, and Spindle Torque Table............................. 45 Wheel Removal: Front or Rear..................................... 45 Tire Pressure.................................................... 46 Tire Inspection.................................................. 46 ENGINE................................................................... 48 Specifications....................................................... 50 Torque Specifications............................................ 50 ES50PL Engine Service Data....................................... 51 ES50PL Engine Service Data....................................... 52 Special Tools.................................................... 53 Engine Fastener Torque Patterns.................................. 53 General Engine Service............................................... 53 Piston Identification............................................ 53 Compression Test................................................. 53 Coolant Temperature Sensor (Thermistor).......................... 54 Cooling System................................................... 54 Radiator Cap / System Pressure Test.............................. 54 Cooling System Specifications.................................... 54 Accessible Components............................................ 55 Engine Removal................................................... 55 Engine Installation Notes........................................ 56 Crankshaft Straightening......................................... 57 ES50PL Engine Lubrication........................................ 57 Oil Pressure Test................................................ 57 Oil Pump Priming Procedure....................................... 58 Oil Flow - ES50PL................................................ 58 ES50PL Oil Flow Chart............................................ 59 ES50PL Engine Exploded Views..................................... 60 Upper Engine Disassembly............................................. 61 Disassembly...................................................... 61 Cam Chain Tensioner Removal...................................... 61 Cam Chain Tensioner Inspection and Reassembly.................... 61 Camshaft Removal................................................. 62 Automatic Compression Release Inspection......................... 62 Camshaft Inspection.............................................. 63 Cylinder Head Removal............................................ 63 Cylinder and Piston Removal...................................... 64 Piston Removal................................................... 64 Piston and Rod Inspection........................................ 65 Lower Engine Disassembly............................................. 66 Crankcase Disassembly and Inspection............................. 66 Starter Drive Gears Removal and Inspection....................... 66 Flywheel / One-Way Starter Clutch Removal and Inspection......... 66 Crankshaft Nut Removal........................................... 67 Clutch Cover / Clutch Removal and Inspection..................... 67 Shifter Component Removal and Inspection......................... 69 Oil Pump Removal and Inspection.................................. 70 Crankshaft Drive and Cam Gear Removal............................ 70 Cam Chain / Tensioner Blade Removal.............................. 71 Crankcase Separation............................................. 71 Crankcase Inspection............................................. 72 Crankcase Bearing Inspection / Removal / Installation............ 72 Transmission and Crankshaft Service.................................. 73 Transmission Removal and Inspection.............................. 73 Transmission Main Shaft Disassembly / Assembly................... 73 Transmission Reassembly.......................................... 74 Crankshaft Removal / Installation................................ 76 Crankshaft Inspection............................................ 76 Engine Reassembly.................................................... 77 Crankcase Reassembly............................................. 77 Piston Installation.............................................. 78 Piston Ring Installation......................................... 78 Cylinder Installation............................................ 79 Cam Chain Installation........................................... 79 Camshaft Timing.................................................. 79 Primary Drive Gear Installation.................................. 80 Outlaw Cam Timing Exploded View.................................. 81 Cylinder Head Service................................................ 82 Cylinder Head Inspection......................................... 82 Cylinder Head Warp............................................... 82 Cylinder Head Disassembly........................................ 82 Cylinder Head Valve Guide / Valve Seat Inspection................ 83 Valve Guide Removal / Installation / Ream........................ 83 Valve Seat Reconditioning........................................ 84 Valve Inspection................................................. 86 ES50PL Adjusting Pad Selection Matrix............................ 87 Cylinder Head Assembly........................................... 88 Cylinder Head Installation....................................... 89 Cylinder Service..................................................... 89 Cylinder Inspection.............................................. 89 Piston-to-Cylinder Clearance..................................... 90 Cylinder Hone Selection and Honing Procedure..................... 90 Honing To Deglaze................................................ 90 Piston Ring Installed Gap........................................ 91 Water Pump Service................................................... 91 Oil Seal / Mechanical Seal Removal (Engine Disassembled)......... 91 Water Pump Mechanical Seal Installation.......................... 91 Mechanical Seal Removal and Installation (Engine Assembled)...... 92 Troubleshooting...................................................... 93 Engine........................................................... 93 Spark Plug Fouling............................................... 95 Cooling System................................................... 95 FUEL SYSTEM / CARBURETION................................................ 96 Fuel System and Carburetion.......................................... 97 BSR 42 Carburetor Exploded View.................................. 97 Fuel Tank Assembly............................................... 98 Special Tools.................................................... 99 Jetting Guidelines............................................... 99 Carburetor Jetting............................................... 99 Mikuni Jet Part Numbers.......................................... 99 CV Carburetor System.................................................100 Carburetor Function..............................................100 Vent Systems - CV Carburetor.....................................100 Mikuni CV Carburetor Operation...................................100 Pilot (Idle and Slow) System ....................................101 Starter System (Choke or Enrichment).............................102 Float System.....................................................102 Main System......................................................103 Pilot Screw......................................................103 Carburetor Disassembly...........................................104 Carburetor Cleaning..............................................105 Carburetor Inspection............................................105 Carburetor Assembly..............................................106 Float Height Adjustment..........................................106 Fuel Delivery........................................................107 Needle and Seat Leak Test........................................107 Fuel Level test..................................................107 Fuel Pump........................................................108 Fuel Pump Disassembly............................................108 Fuel Pump Inspection / Assembly..................................108 Troubleshooting......................................................108 Fuel Starvation / Lean Mixture...................................108 Rich Mixture.....................................................109 Poor Idle / Idle Too High........................................109 Idle Too Low.....................................................109 Erratic Idle.....................................................109 BODY / STEERING / SUSPENSION.............................................110 General Information..................................................112 Torque Specifications............................................112 Special Tools....................................................112 Body Assembly........................................................113 Exploded View....................................................113 Body Component Removal...............................................114 Seat / Side Panel................................................114 Front Cab........................................................114 Tank Cover.......................................................114 Heel Pocket......................................................115 Rear Cab.........................................................115 Steering Assembly Exploded View......................................116 Steering Knuckle.....................................................117 Removal..........................................................117 Installation.....................................................117 Ball Joint Service...................................................117 Removal..........................................................117 Installation.....................................................118 Front Hub............................................................119 Exploded View....................................................119 Hub Removal......................................................120 Hub Disassembly..................................................121 Hub Assembly.....................................................121 Hub Installation.................................................122 Front Suspension Exploded View.......................................123 Front A-arm Replacement..............................................124 A-arm Removal and Inspection.....................................124 A-arm Installation...............................................124 Rear Suspension Exploded View........................................125 Rear A-arm Replacement...............................................126 A-arm Removal....................................................126 A-arm Inspection.................................................126 A-arm Installation...............................................127 Rear Housing.........................................................128 Exploded View....................................................128 Housing Removal..................................................129 Housing Disassembly / Service....................................130 Assembly.........................................................132 Installation.....................................................133 Rear Bearing Carrier.................................................134 Carrier Removal..................................................134 Carrier Disassembly / Inspection.................................134 Carrier Assembly.................................................135 Carrier Installation.............................................136 Rear Drive (CV) Joint................................................137 CV Joint Removal.................................................137 CV Joint Service.................................................137 CV Boot Replacement..............................................138 CV Joint Installation............................................139 Decals...............................................................140 Replacement......................................................140 Front Shock Exploded View............................................141 RydeFX™ FRONT SHOCK..............................................141 Rear Shock Exploded View.............................................142 RydeFX™ REAR SHOCK (Compression Adjustable)......................142 RydeFX™ Shock Service................................................143 Shock Specification Chart........................................143 Piston Orientation...............................................143 RydeFX™ Shock Rebuild Procedure..................................144 BRAKES...................................................................150 Brake Specifications.................................................151 General Specifications...........................................151 Torque Specifications............................................151 Special Tools....................................................151 Brake Caliper Exploded Views.........................................152 Rear Brake Caliper Assembly......................................152 Front Brake Caliper Assembly.....................................152 Brake System Overview................................................153 Front Brake System - Exploded View...............................153 Rear Brake System - Exploded View................................154 Service Notes....................................................155 Brake Noise Troubleshooting......................................155 Hydraulic System Operation.......................................156 Brake Fluid Replacement and Bleeding Procedure...................157 Master Cylinder......................................................159 Removal..........................................................159 Installation.....................................................160 Front Caliper Service................................................161 Caliper Removal and Disassembly .................................161 Caliper Inspection...............................................162 Caliper Reassembly...............................................163 Caliper Installation.............................................163 Front Brake Pads.....................................................164 Pad Removal......................................................164 Pad Assembly.....................................................165 Brake Burnishing Procedure.......................................165 Front Brake Disc.....................................................166 Disc Inspection..................................................166 Disc Removal / Replacement.......................................166 Rear Caliper Service.................................................167 Caliper Removal..................................................167 Caliper Disassembly..............................................167 Caliper Inspection...............................................168 Caliper Assembly.................................................168 Rear Brake Pad.......................................................169 Pad Removal......................................................169 Pad Installation.................................................170 Rear Brake Disc......................................................171 Disc Inspection..................................................171 Disc Removal.....................................................172 Disc Replacement.................................................172 Troubleshooting......................................................173 Brakes Squeal....................................................173 Poor Brake Performance...........................................173 Lever Vibration..................................................173 Brakes Lock......................................................173 ELECTRICAL...............................................................174 General Information..................................................175 Special Tools....................................................175 Electrical Service Notes.........................................175 Timing Check Procedure...........................................175 Lighting and Controls................................................176 Neutral / Reverse Position Indicator Switch Test.................176 Headlight Lamp Replacement.......................................176 Headlamp Switch Test.............................................176 Headlight Housing Replacement....................................176 Headlight Adjustment.............................................177 Taillight / Brakelight Lamp Replacement..........................177 Brake Light Switch Tests.........................................178 Clutch Switch Test...............................................178 Indicator Lamp Replacement.......................................178 Tether Switch Test (Accessory Option)............................179 Electronic Throttle Control (ETC) Switch.........................179 ETC Operation Test...............................................179 Ignition System......................................................180 Ignition System Troubleshooting..................................180 Circuit Breakers.................................................180 Cranking Output Tests............................................180 Flywheel Identification..........................................181 DC / CDI Ignition................................................181 Ignition System Testing..........................................182 Components of DC / CDI Ignition..................................183 Cooling System.......................................................184 Fan Control Circuit Operation / Testing..........................184 Coolant Temperature Sensor Test (Hot Light)......................184 Fan Control Switch Bypass Test...................................184 Coolant Fan Control Switch Operation Test........................185 Fan Motor Current Draw...........................................185 Charging System......................................................185 Current Draw - Key Off...........................................185 Charging System “Break Even” Test................................186 Alternator Tests (Charging System)...............................186 Charging System Testing Flow Chart...............................187 Battery Service......................................................188 Battery Maintenance..............................................188 Battery Inspection / Removal.....................................188 Battery Terminals / Bolts........................................189 Battery Testing..................................................189 OCV - Open Circuit Voltage Test..................................189 Load Test........................................................189 Off Season Storage...............................................189 Charging Procedure...............................................190 Starting System......................................................190 Starter System Troubleshooting...................................190 Clutch Switch Test...............................................191 Neutral Start Diode Test ........................................191 Starter Voltage Drop Testing.....................................191 Starter Motor Disassembly........................................191 Brush Inspection / Replacement...................................192 Armature Testing.................................................192 Starter Reassembly...............................................193 Starter One-Way Clutch Inspection................................193 Starter System Testing Flow Chart ...............................194 INDEX....................................................................196 WIRE DIAGRAM (Main)......................................................200 WIRE DIAGRAM (Breakouts).................................................202
G.B 05/04/25
