The Polaris Outlaw 500, produced from 2006 to 2007, promised a thrilling blend of sport ATV performance and trail-friendly usability. However, like many machines, it wasn't without its quirks and potential headaches. Understanding the common problems associated with the Outlaw 500 can save you time, money, and frustration, whether you're a current owner or considering buying one. This knowledge empowers you to make informed decisions about maintenance, repairs, and overall ownership.

So, What's the Deal with the Outlaw 500? Common Issues You Might Encounter

The Outlaw 500, despite its sporty aspirations, shares its engine with the Polaris Predator 500. This is generally a positive, as the engine itself is relatively robust. The problems often stem from peripheral components and the way the ATV was assembled and used. Let's dive into some of the most frequently reported issues:

  • Starting Problems (Especially When Cold): This is a very common complaint. The Outlaw 500 can be notoriously difficult to start in cold weather.
  • Overheating: While not universal, overheating is a concern, particularly during slow, technical riding or in hot climates.
  • Carburetor Issues: The carburetor, a Mikuni BST40, is prone to clogging and requires regular cleaning.
  • Weak Battery/Charging System: The battery can struggle to hold a charge, and the charging system sometimes fails to keep up with electrical demands.
  • Rear Suspension Linkage Wear: The rear suspension linkage, specifically the bearings and seals, are susceptible to wear and tear, leading to sloppy handling.
  • Electrical Gremlins: Intermittent electrical problems, such as lights flickering or the engine cutting out, can be frustrating to diagnose.

Digging Deeper: Troubleshooting Those Pesky Starting Problems

Cold starting issues are arguably the most irritating problem Outlaw 500 owners face. Here's a breakdown of potential causes and solutions:

  1. Valve Adjustment: This is the first thing you should check. Incorrect valve clearances are a primary culprit for hard starting, especially when cold. The valves may not be seating properly, leading to a loss of compression.
  2. Carburetor Problems:
    • Choke Functionality: Ensure the choke is functioning correctly. The cable might be stretched or the choke valve itself could be sticking.
    • Pilot Jet Clogging: The pilot jet is responsible for fuel delivery at idle and low speeds. A clogged pilot jet will severely impact cold starting. Clean it thoroughly using carburetor cleaner and compressed air.
    • Air/Fuel Mixture: The air/fuel mixture screw might need adjustment. Refer to the service manual for the recommended setting.
  3. Battery Condition: A weak battery simply won't provide enough cranking power to start the engine, especially in cold temperatures. Have the battery load tested to determine its health.
  4. Spark Plug: A fouled or worn spark plug can make starting difficult. Replace the spark plug with the recommended type and gap.
  5. Compression Test: If you've addressed the above issues and the engine still won't start, perform a compression test. Low compression indicates worn piston rings, valves, or cylinder walls.
  6. Fuel Quality: Stale or contaminated fuel can cause starting problems. Drain the fuel tank and refill it with fresh fuel. Consider adding a fuel stabilizer.

Keeping Your Cool: Addressing Overheating Issues

Overheating can damage your engine, so it's crucial to address this problem promptly. Here's what to investigate:

  1. Coolant Level: Check the coolant level in the radiator and overflow reservoir. Top up as needed with the correct type of coolant.
  2. Radiator Condition: Inspect the radiator for debris, such as mud, leaves, or insects, blocking airflow. Clean the radiator fins carefully with a soft brush and water.
  3. Radiator Cap: A faulty radiator cap can prevent the cooling system from pressurizing properly, leading to overheating. Have the cap pressure tested or replace it.
  4. Water Pump: The water pump circulates coolant through the engine. A failing water pump will cause overheating. Check for coolant leaks around the water pump and listen for unusual noises.
  5. Lean Fuel Mixture: A lean fuel mixture (too much air, not enough fuel) can cause the engine to run hot. Adjust the carburetor accordingly.
  6. Timing: Incorrect ignition timing can also contribute to overheating. Check the timing and adjust it to the factory specification.

Carburetor Cleaning and Maintenance: Keeping the Fuel Flowing

The Mikuni BST40 carburetor on the Outlaw 500 is a common source of problems. Regular cleaning and maintenance are essential to keep it running smoothly.

  1. Disassembly: Carefully disassemble the carburetor, taking note of the location of all parts.
  2. Cleaning: Clean all carburetor components with carburetor cleaner. Pay particular attention to the jets, passages, and float bowl. Use compressed air to blow out any remaining debris.
  3. Inspection: Inspect all carburetor components for wear or damage. Replace any worn or damaged parts.
  4. Reassembly: Reassemble the carburetor carefully, ensuring that all parts are properly installed.
  5. Adjustment: Adjust the air/fuel mixture screw to the recommended setting.

Important Note: When working on the carburetor, it's crucial to use a clean workspace and avoid contaminating the parts with dirt or debris. It's also a good idea to have a service manual on hand for reference.

Battery and Charging System Woes: Staying Charged Up

A weak battery or a faulty charging system can leave you stranded. Here's how to troubleshoot these issues:

  1. Battery Load Test: Have the battery load tested to determine its health. A load test simulates the battery's performance under load and provides a more accurate assessment of its condition than a simple voltage test.
  2. Charging System Voltage Test: Use a multimeter to check the charging system voltage at the battery terminals while the engine is running. The voltage should be between 13.5 and 14.5 volts.
  3. Stator Test: The stator is responsible for generating electricity for the charging system. If the charging system voltage is low, the stator may be faulty. Use a multimeter to test the stator output according to the service manual.
  4. Regulator/Rectifier Test: The regulator/rectifier regulates the voltage from the stator and converts it from AC to DC. A faulty regulator/rectifier can cause overcharging or undercharging. Test the regulator/rectifier according to the service manual.
  5. Wiring Inspection: Inspect the wiring harness for loose connections, damaged wires, or corrosion. Clean and tighten any loose connections and repair any damaged wires.

Rear Suspension Linkage: Keeping it Smooth and Responsive

The rear suspension linkage on the Outlaw 500 is prone to wear and tear, especially in harsh riding conditions. This can lead to sloppy handling and reduced suspension performance.

  1. Inspection: Inspect the rear suspension linkage for play or looseness. Check the bearings and seals for wear or damage.
  2. Lubrication: Regularly lubricate the rear suspension linkage with a high-quality grease.
  3. Bearing and Seal Replacement: If the bearings or seals are worn or damaged, replace them.
  4. Torque Specifications: When reassembling the rear suspension linkage, be sure to tighten all fasteners to the correct torque specifications.

Electrical Gremlins: Hunting Down Those Elusive Problems

Intermittent electrical problems can be frustrating to diagnose. Here are some tips for tracking them down:

  1. Wiring Diagram: Obtain a wiring diagram for the Outlaw 500. This will help you understand the electrical system and trace circuits.
  2. Visual Inspection: Carefully inspect the wiring harness for loose connections, damaged wires, or corrosion.
  3. Multimeter Testing: Use a multimeter to test circuits for continuity and voltage.
  4. Component Isolation: Isolate individual components to determine if they are causing the problem.
  5. Grounding Issues: Check for proper grounding. A poor ground connection can cause a variety of electrical problems.

Frequently Asked Questions

  • Why is my Outlaw 500 so hard to start when it's cold? Valve adjustment is the most common culprit. Also, check the carburetor (especially the choke and pilot jet) and battery condition.
  • My Outlaw 500 is overheating. What should I do? First, check the coolant level and radiator condition. If those are okay, investigate the radiator cap, water pump, and fuel mixture.
  • How often should I clean my Outlaw 500 carburetor? At least once a year, or more frequently if you ride in dusty or muddy conditions.
  • What kind of oil should I use in my Outlaw 500? Use a high-quality 10W-40 motorcycle oil that meets JASO MA specifications.
  • Where can I find a service manual for my Outlaw 500? You can often find digital copies online through forums or specialized websites. Paper copies can be purchased from various online retailers.

Conclusion

While the Polaris Outlaw 500 can present some challenges, understanding its common problems allows you to proactively address potential issues and keep your ATV running smoothly. Regular maintenance, careful troubleshooting, and a willingness to learn will help you enjoy the Outlaw 500's sporty performance for years to come. Remember to consult a qualified mechanic if you're not comfortable performing repairs yourself.