Polaris Outlaw 500 ATV Repair Service Manual 2006-2007

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This workshop repair service manual PDF download for the 2006-2007 Polaris Outlaw 500 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

MODEL: 2006- 2007 OUTLAW 500
MODEL NUMBER: A06(07)GP50AA,AB
ENGINE MODEL: ES500PLE041


TABLE OF CONTENTS :

GENERAL INFORMATION 
MAINTENANCE 
ENGINE 
FUEL SYSTEM 
BODY / STEERING / SUSPENSION 
BRAKES 
ELECTRICAL 
WIRE DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 202


This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. 

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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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)

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