Polaris Outlaw 500 - Repair, Service Manual, Wiring Diagrams and Owners Manual

CLICK HERE FOR SAMPLE MANUAL

POLARIS OUTLAW 500 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for ATV Polaris Outlaw 500.

 
CONTENTS:

SERVICE MANUAL

2006-2007 Polaris Outlaw 500 Service Manual
- Foreward
- Manual Safety Labels and Directions
- Trademarks
Table
General Information
- Vehicle Identification
- Model Identification
- Engine Designation Number
- VIN Identification
- Unit Serial Number (VIN) Location
- Engine Serial Number Location
- Vehicle Information
- Paint Codes
- Replacement Keys
- Publication Numbers
- Standard Torque Specifications
- Specifications
- MODEL: 2007 OUTLAW 500
- 2007 OUTLAW 500
- Special Tools
- ‘Where Used’ Table
- Special Tool Listing
- Misc. Numbers / Charts
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
- Coversion Table
- Glossary of Terms
Maintenance
- Periodic Maintenance Chart
- Periodic Maintenance Overview
- Maintenance Chart Key
- Pre-Ride Maintenance Interval
- Recommended Pre-Ride Fluid Level Checks
- 0 - 50 Hour Maintenance Interval
- 50 - 100 Hour Maintenance Interval
- 100 - 300 Hour Maintenance Interval
- Maintenance References
- Lubricants and Service Products
- Polaris Lubricants, Maintenance and Service Products
- General Vehicle Inspection and Maintenance
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
- Fuel System and Air Intake
- Fuel System
- Fuel Lines
- Vent Lines
- Fuel Valve
- Carburetor Draining
- Carburetor Pilot Screw Adjustment
- Idle Speed Adjustment
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC) Adjustment
- Choke Adjustment
- Air Filter and Pre-filter Service
- Air Box Drain Tube
- Crankcase Breather Filter Inspection
- Engine and Transmission
- Engine Oil Level Check
- Engine Oil and Filter Service
- Oil Pump Priming Procedure
- Compression Test
- Exhaust Pipe / Spark Arrestor
- Engine Mount Locations
- Liquid Cooling System
- Cooling System Overview
- Coolant Strength / Type
- Cooling System Hoses
- Radiator
- Recovery Bottle Coolant Level Inspection
- Cooling System Pressure Test
- Radiator Screen Removal
- Final Drive
- Clutch Adjustment
- Reverse Lock-Out Lever Inspection and Cable Adjustment
- Sprocket Inspection
- Drive Chain Inspection / Replacement
- Drive Chain Tension
- Drive Chain Adjustment
- Rear Driveshaft Boot Inspection
- Rear Driveshaft Boot “Pressure Equalizing”
- Electrical and Ignition System
- Battery Maintenance
- Battery Inspection / Removal
- Battery Terminals / Bolts
- Off Season Storage
- Engine- To- Frame Ground
- Charging Procedure
- Spark Plug Inspection
- Ignition Timing
- Steering and Suspension
- Steering
- Controls
- Wheel Alignment
- Steering Inspection / Tie Rod Ends and Hubs
- Toe Alignment Adjustment
- Camber and Caster
- Suspension Spring Preload Adjustment
- Rear Shock Compression Adjustment
- Brake System
- Brake System Inspection
- Hose / Fitting Inspection
- Brake Pad Inspection
- Brake Testing
- Wheels and Tires
- Wheels
- Wheel, Hub, and Spindle Torque Table
- Wheel Removal: Front or Rear
- Tire Pressure
- Tire Inspection
Engine
- Specifications
- Torque Specifications
- ES50PL Engine Service Data
- ES50PL Engine Service Data
- Special Tools
- Engine Fastener Torque Patterns
- General Engine Service
- Piston Identification
- Compression Test
- Coolant Temperature Sensor (Thermistor)
- Cooling System
- Radiator Cap / System Pressure Test
- Cooling System Specifications
- Accessible Components
- Engine Removal
- Engine Installation Notes
- Crankshaft Straightening
- ES50PL Engine Lubrication
- Oil Pressure Test
- Oil Pump Priming Procedure
- Oil Flow - ES50PL
- ES50PL Oil Flow Chart
- ES50PL Engine Exploded Views
- Upper Engine Disassembly
- Disassembly
- Cam Chain Tensioner Removal
- Cam Chain Tensioner Inspection and Reassembly
- Camshaft Removal
- Automatic Compression Release Inspection
- Camshaft Inspection
- Cylinder Head Removal
- Cylinder and Piston Removal
- Piston Removal
- Piston and Rod Inspection
- Lower Engine Disassembly
- Crankcase Disassembly and Inspection
- Starter Drive Gears Removal and Inspection
- Flywheel / One-Way Starter Clutch Removal and Inspection
- Crankshaft Nut Removal
- Clutch Cover / Clutch Removal and Inspection
- Shifter Component Removal and Inspection
- Oil Pump Removal and Inspection
- Crankshaft Drive and Cam Gear Removal
- Cam Chain / Tensioner Blade Removal
- Crankcase Separation
- Crankcase Inspection
- Crankcase Bearing Inspection / Removal / Installation
- Transmission and Crankshaft Service
- Transmission Removal and Inspection
- Transmission Main Shaft Disassembly / Assembly
- Transmission Reassembly
- Crankshaft Removal / Installation
- Crankshaft Inspection
- Engine Reassembly
- Crankcase Reassembly
- Piston Installation
- Piston Ring Installation
- Cylinder Installation
- Cam Chain Installation
- Camshaft Timing
- Primary Drive Gear Installation
- Outlaw Cam Timing Exploded View
- Cylinder Head Service
- Cylinder Head Inspection
- Cylinder Head Warp
- Cylinder Head Disassembly
- Cylinder Head Valve Guide / Valve Seat Inspection
- Valve Guide Removal / Installation / Ream
- Valve Seat Reconditioning
- Valve Inspection
- ES50PL Adjusting Pad Selection Matrix
- Cylinder Head Assembly
- Cylinder Head Installation
- Cylinder Service
- Cylinder Inspection
- Piston-to-Cylinder Clearance
- Cylinder Hone Selection and Honing Procedure
- Honing To Deglaze
- Piston Ring Installed Gap
- Water Pump Service
- Oil Seal / Mechanical Seal Removal (Engine Disassembled)
- Water Pump Mechanical Seal Installation
- Mechanical Seal Removal and Installation (Engine Assembled)
- Troubleshooting
- Engine
- Spark Plug Fouling
- Cooling System
Fuel System / Carburetion
- Fuel System and Carburetion
- BSR 42 Carburetor Exploded View
- Fuel Tank Assembly
- Special Tools
- Jetting Guidelines
- Carburetor Jetting
- Mikuni Jet Part Numbers
- CV Carburetor System
- Carburetor Function
- Vent Systems - CV Carburetor
- Mikuni CV Carburetor Operation
- Pilot (Idle and Slow) System
- Starter System (Choke or Enrichment)
- Float System
- Main System
- Pilot Screw
- Carburetor Disassembly
- Carburetor Cleaning
- Carburetor Inspection
- Carburetor Assembly
- Float Height Adjustment
- Fuel Delivery
- Needle and Seat Leak Test
- Fuel Level test
- Fuel Pump
- Fuel Pump Disassembly
- Fuel Pump Inspection / Assembly
- Troubleshooting
- Fuel Starvation / Lean Mixture
- Rich Mixture
- Poor Idle / Idle Too High
- Idle Too Low
- Erratic Idle
Body / Steering / Suspension
- General Information
- Torque Specifications
- Special Tools
- Body Assembly
- Exploded View
- Body Component Removal
- Seat / Side Panel
- Front Cab
- Tank Cover
- Heel Pocket
- Rear Cab
- Steering Assembly Exploded View
- Steering Knuckle
- Removal
- Installation
- Ball Joint Service
- Removal
- Installation
- Front Hub
- Exploded View
- Hub Removal
- Hub Disassembly
- Hub Assembly
- Hub Installation
- Front Suspension Exploded View
- Front A-arm Replacement
- A-arm Removal and Inspection
- A-arm Installation
- Rear Suspension Exploded View
- Rear A-arm Replacement
- A-arm Removal
- A-arm Inspection
- A-arm Installation
- Rear Housing
- Exploded View
- Housing Removal
- Housing Disassembly / Service
- Assembly
- Installation
- Rear Bearing Carrier
- Carrier Removal
- Carrier Disassembly / Inspection
- Carrier Assembly
- Carrier Installation
- Rear Drive (CV) Joint
- CV Joint Removal
- CV Joint Service
- CV Boot Replacement
- CV Joint Installation
- Decals
- Replacement
- Front Shock Exploded View
- RydeFX™ FRONT SHOCK
- Rear Shock Exploded View
- RydeFX™ REAR SHOCK (Compression Adjustable)
- RydeFX™ Shock Service
- Shock Specification Chart
- Piston Orientation
- RydeFX™ Shock Rebuild Procedure
Brakes
- Brake Specifications
- General Specifications
- Torque Specifications
- Special Tools
- Brake Caliper Exploded Views
- Rear Brake Caliper Assembly
- Front Brake Caliper Assembly
- Brake System Overview
- Front Brake System - Exploded View
- Rear Brake System - Exploded View
- Service Notes
- Brake Noise Troubleshooting
- Hydraulic System Operation
- Brake Fluid Replacement and Bleeding Procedure
- Master Cylinder
- Removal
- Installation
- Front Caliper Service
- Caliper Removal and Disassembly
- Caliper Inspection
- Caliper Reassembly
- Caliper Installation
- Front Brake Pads
- Pad Removal
- Pad Assembly
- Brake Burnishing Procedure
- Front Brake Disc
- Disc Inspection
- Disc Removal / Replacement
- Rear Caliper Service
- Caliper Removal
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Rear Brake Pad
- Pad Removal
- Pad Installation
- Rear Brake Disc
- Disc Inspection
- Disc Removal
- Disc Replacement
- Troubleshooting
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Brakes Lock
Electrical
- General Information
- Special Tools
- Electrical Service Notes
- Timing Check Procedure
- Lighting and Controls
- Neutral / Reverse Position Indicator Switch Test
- Headlight Lamp Replacement
- Headlamp Switch Test
- Headlight Housing Replacement
- Headlight Adjustment
- Taillight / Brakelight Lamp Replacement
- Brake Light Switch Tests
- Clutch Switch Test
- Indicator Lamp Replacement
- Tether Switch Test (Accessory Option)
- Electronic Throttle Control (ETC) Switch
- ETC Operation Test
- Ignition System
- Ignition System Troubleshooting
- Circuit Breakers
- Cranking Output Tests
- Flywheel Identification
- DC / CDI Ignition
- Ignition System Testing
- Components of DC / CDI Ignition
- Cooling System
- Fan Control Circuit Operation / Testing
- Coolant Temperature Sensor Test (Hot Light)
- Fan Control Switch Bypass Test
- Coolant Fan Control Switch Operation Test
- Fan Motor Current Draw
- Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Alternator Tests (Charging System)
- Charging System Testing Flow Chart
- Battery Service
- Battery Maintenance
- Battery Inspection / Removal
- Battery Terminals / Bolts
- Battery Testing
- OCV - Open Circuit Voltage Test
- Load Test
- Off Season Storage
- Charging Procedure
- Starting System
- Starter System Troubleshooting
- Clutch Switch Test
- Neutral Start Diode Test
- Starter Voltage Drop Testing
- Starter Motor Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter One-Way Clutch Inspection
- Starter System Testing Flow Chart
Index
Wire Diagram (Main)
Wire Diagram (Breakouts)

OWNERS MANUAL