Polaris Outlaw 500 User Manual

3.6
ENGINE
Special Tools
Engine Fastener Torque Patterns
Tighten cylinder head, cylinder base, and crankcase fasteners
following the sequence outlined below.
GENERAL ENGINE SERVICE
Piston Identification
The piston may or may not have an identification mark for
piston placement. If the piston has an identification mark, follow
the directions for piston placement below. If the piston does not
have an identification mark, the direction for placement of the
piston does not matter.
NOTE: Note the directional and identification marks
when viewing the pistons from the top. Identifying
marks such as “F”, “J”, “X“or
Q must always be
positioned to the flywheel side of the engine. Other
marks are used for identification as to diameter,
length and design. Four stroke engine rings are a
rectangular profile. See text for oil control ring rail
installation. Use the information below to identify
pistons and rings:
Compression Test
NOTE: This engine has built-in decompression
components. Compression readings will vary in
proportion to cranking speed during the test.
Average compression (measured) is about 85-90 psi
@ 400 RPM during a compression test.
A cylinder leakdown test is the best indication of engine
condition. Follow manufacturer’s instructions to perform a
cylinder leakage test. Never use high pressure leakage testers,
as crankshaft seals may dislodge and leak.
PART NUMBER TOOL DESCRIPTION
2872105
Water Pump Mechanical
Seal Puller
2200634
Valve Seat Reconditioning
Kit
2870390 Piston Support Block
PA-45958
Cam Chain Tensioner
Assembly Tool
PA-46075 Flywheel Puller
PA- 46076
MAG End Crankshaft Nut
Remover/Installer
PA-46087 Crankcase Separator
PA-46077
MAG End Crankshaft
Installer
2871283
Crankshaft/Water Pump
Seal Install Kit
5131135 Water Pump Install Kit
PA-46502 Valve Spring Compressor
Cylinder Head & Cylinder Base
3
2
5
1
4
6
8 mm
1
2
3
4
5
6
7
8
9
10
11
12
13
Cylinder Compression w / decompression
Standard: 85-90 PSI @ 400 RPM
Cylinder Leakdown
Service Limit: 10%
(Inspect for cause if leakage exceeds 10%)
RepairPro Service Manual

Polaris Outlaw 500 Specifications

General

Brand	Polaris
Model	Outlaw 500
Category	Offroad Vehicle
Language	English