2006-2007 Polaris Outlaw 500 Service Repair Workshop Manual

1 GENERAL INFORMATION 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEM 5 BODY / STEERING / SUSPENSION 6 BRAKES 7 ELECTRICAL 8 WIRE DIAGRAMS

GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMATION 1 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 UNIT SERIAL NUMBER (VIN) LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 2006-2007 OUTLAW 500. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 ‘WHERE USED’ TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOL LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MISC. NUMBERS / CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 COVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12

1.2 GENERAL INFORMATION VEHICLE IDENTIFICATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Engine Designation Number ES50PLE - Single, Water Cooled, Electric Start, 5-Speed Manual, DOHC 4 Stroke. VIN Identification Unit Serial Number (VIN) Location Whenever corresponding with Polaris about a particular issue, the machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the left side of the frame tube. (1) Engine Serial Number Location This information can be found on the clutch housing on the right side of engine. (2) VEHICLE INFORMATION Paint Codes Replacement Keys Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. } Machine Model Number Identification } } } A 07 GP 50 AA Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine 4 X A G P 5 0 A * 7 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Emissions } Check Digit* Model Year Body Style Plant No* Individual Serial Number * -This could be either a number or a letter Powertrain PAINTED PART COLOR POLARIS Frame Cloud Silver P-385 Frame Matte Black P-458 SERIES # PART NUMBER 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 RepairPro Service Manual

1.3 GENERAL INFORMATION 1 Standard Torque Specifications The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS, refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections.

1.4 GENERAL INFORMATION SPECIFICATIONS MODEL: 2006- 2007 OUTLAW 500 MODEL NUMBER: A06(07)GP50AA,AB ENGINE MODEL: ES500PLE041 Category Dimension Length 71.5 in. / 182 cm Width 47.5 in. / 121 cm Height 45 in. / 114 cm Minimum Turing Radius 67 in. / 170 cm Wheel Base 51 in. / 130 cm Ground Clearance 11.5 in. / 29 cm Dry Weight 439 lbs. / 199 kg Gross Vehicle Weight 645 lbs. / 292 kg Oil Capacity 2 qts. / 1.9 ltr Coolant Capacity 2.25 qts. / 2.1 ltr Fuel Capacity 3.25 gal. / 12.3 ltr RepairPro Service Manual

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

1.6 GENERAL INFORMATION SPECIAL TOOLS ‘Where Used’ Table *Special Tools can be ordered through a Polaris Dealer or SPX Corporation (1-800-328-6657). PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 8712100 or 8712500 Tachometer 2,7 2200634 Valve Seat Reconditioning Kit 3 PU-45257 Valve Spring Compressor 3 PA-46075 Flywheel Puller 3 PA-46087 Crankcase Separator 3 2870390 Piston Support Block 3 2872105 Water Pump Mechanical Seal Puller 3 PA-45958 Cam Chain Tensioner Assembly Tool 3 PA-46076 MAG End Crankshaft Nut Remover/Installer 3 PA-46077 MAG End Crankshaft Installer 3 2871283 Crankshaft/Water Pump Seal Install Kit 3 5131135 Water Pump Install Kit 3 PA-46502 Valve Spring Compressor 3 2870975 Mity Vac™ Pressure Test Tool 3,4 2872314 Carburetor Float Adjustment Tool 4 PS-45259 Gas Fill Tool 5 PS-45261 IFP Positioning / Extraction Tool 5 PA-48282 Rear Hub Tool 5 PV-43568 Fluke™ 77 Digital Multimeter 7 2870630 Timing Light 7 RepairPro Service Manual

1.7 GENERAL INFORMATION 1 Special Tool Listing Special Tools may be required while servicing your machine. Some of the tools listed are mandatory and other tools may be substituted with a similar tool, if available. Tools shown may not apply to a particular vehicle. Polaris recommends the use of Polaris special tools when servicing any Polaris product. Standard Tools and Engine Tools PU-45432 - Caliper or A Basic Caliper Basic Micrometer PA-46502 - Valve Spring Compressor PA-46087 - Crankcase Separator PA-46075 - Flywheel Puller PA-45958 - Cam Chain Tensioner Tool Standard Tools and Engine Tools 2870569 - Crankshaft True Kit 2870386 - Piston Pin Puller PA-46076 Mag End Crank Nut Remover/Install PA-46077 - Mag End Crankshaft Installer PV-43527 Oil Filter Wrench 5131135 - Water Pump Install Tool 2870390 - Piston Support Block

1.8 GENERAL INFORMATION Standard Tools and Engine Tools 2870303 - Hone Kit 2870305 - Stone Replacement Kit 2870588 - Hone Oil (12 OZ.) 2200634 - Valve Seat Reconditioning Kit 2870459 - Dial Indicator PV-35667-A - Cylinder Leak down Tester 2872105 - Water Pump Seal Puller 2871283 - Crank/Water Pump Seal Install Kit Suspension Tools PS-45261 - Shock IFP Positioning / Extraction Tool PS-45259 - Gas Fill Tool Final Drive PA-48282 Rear Hub Tool RepairPro Service Manual

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2006-2007 Polaris Outlaw 500 Service Repair Workshop Manual

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