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Polaris Outlaw 500 User Manual

Polaris Outlaw 500
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3.16
ENGINE
Camshaft Inspection
1. Visually inspect each cam lobe for wear, chafing or
damage.
NOTE: Camshafts, gears and bearings are not
serviceable. Replace camshaft as an assembly if
problems are found.
2. Inspect the cam bearings for excess play or noise during
rotation.
3. Measure height of each cam lobe using a micrometer.
Compare to specifications.
4. Measure camshaft journal outside diameter (O.D.)
5. Measure ID of camshaft journal bore.
NOTE: Replace camshaft as an assembly if
damaged or if any part is worn past the service limit.
6. Calculate oil clearance by subtracting journal OD from
journal bore ID. Compare to specifications.
NOTE: Replace cylinder head if camshaft journal
bore is damaged or worn excessively.
Cylinder Head Removal
1. Remove the cam shafts.
2. Remove the two 8mm flange bolts (A) from cylinder head.
3. Loosen each of the four cylinder head bolts (B) with a
14mm 12-point socket, turning evenly 1/8 turn each time
in a criss–cross pattern until loose.
4. Remove bolts (B) and tap cylinder head lightly with a soft-
face hammer until loose.
5. Remove cylinder head and head gasket.
Camshaft Lobe Height
Limit: 1.6555ð (42.05 mm)
Camshaft Journal O.D.:
Mag End: .9821- .9828ð
(24.946- 24.963 mm)
Check for wear
or roughness
Journal O.D.
Camshaft Journal I.D.:
Mag End: .9842- .9851ð
(25.00- 25.021 mm)
Camshaft Oil Clearance
Limit: .0039ð (.10 mm)
CAUTION
Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid
damaging the head.
A
B
RepairPro Service Manual

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Polaris Outlaw 500 Specifications

General IconGeneral
BrandPolaris
ModelOutlaw 500
CategoryOffroad Vehicle
LanguageEnglish

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