Polaris Outlaw Service 2009 Service manual

Polaris Outlaw Service · 2009 · service manual · 273 pages

Technical data

Numbers below were extracted automatically from the document. Verify them against the original manual before you order parts or apply torque.

Tightening torque

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Hose clamp4.1 N·m4 N·mp. 31
Pivot mounting bolts40.7 N·m41 N·mp. 37
Chain adjusting bolt27.1 N·m27 N·mp. 37
Front two bolts14.9 N·m15 N·mp. 42
Front Spindle Nut54.2 N·m55 N·mp. 51
Rear Hub Nut108.5 N·m109 N·mp. 51
Rear Hub Nut122 N·m122 N·mp. 51
Serious engine damage can result25 N·mp. 59
Shock Bolts44.7 N·m33 ft·lbp. 68
Front Suspension45 N·mp. 68
Shock Bolts48.8 N·m36 ft·lbp. 68
Stud Nut40.7 N·m30 ft·lbp. 68
Front Spindle Nut23 N·m17 ft·lbp. 68
Tie Rod End Attaching Nut43.4 N·m32 ft·lbp. 68
Tie Rod End Attaching Nut24.4 N·m18 ft·lbp. 68
Caliper Mounting Bolts24 N·mp. 68
Steering24.4 N·m18 ft·lbp. 68
Handlebar Adjuster Block15 N·mp. 68
Steering Post Bushing Nuts23 N·m17 ft·lbp. 68
Rear Axle Nut Pinch Bolt5.6 N·m50 in·lbp. 68
Rear Axle Housing Pinch Bolts47.5 N·m35 ft·lbp. 68
Swing Arm Pivot Bolt / Rear128.8 N·m95 ft·lbp. 68
Engine Mount129 N·mp. 68
Rear Hub Nut45 N·mp. 68
Rear Hub Nut40.7 N·m30 ft·lbp. 68
Rear Hub Carrier Bolts41 N·mp. 68
Rear Hub Carrier Bolts45 N·mp. 68
D. Steering Post14.9 N·m11 ft·lbp. 72
Inner Spacer51.5 N·m38 ft·lbp. 78
Brackets23 N·m17 ft·lbp. 89
Upper / Lower Control Arm44.7 N·m45 N·mp. 92
Securing corner housing122 N·m122 N·mp. 92
Clamp122 N·m122 N·mp. 95
F. Thrust Bushing48.8 N·m36 ft·lbp. 96
Washer49 N·mp. 96
H. Nylok Nut48.8 N·m36 ft·lbp. 96
I. Chain Guide49 N·mp. 96
Hex pinch bolt5.6 N·m6 N·mp. 100
Socket headed locking screw13.6 N·m14 N·mp. 101
Preload Ring13.6 N·m14 N·mp. 104
Valve Nut16.3 N·m17 N·mp. 110
Front Brake Caliper Assembly5.3 N·m47 in·lbp. 135
Rear Brake Caliper Assembly5.3 N·m47 in·lbp. 135
Bleeder screw5.3 N·m5.3 N·mp. 142
Master Cylinder20.3 N·m15 ft·lbp. 144
Front Brake Line9.6 N·m85 in·lbp. 144
Banjo Bolt20.3 N·m15 ft·lbp. 144
Mount Bolt20.3 N·m15 ft·lbp. 144
Mount Bolt52 N·mp. 144
Brake switch bolt20.3 N·m20 N·mp. 144
Cover Screws1.2 N·m1.24 N·mp. 144
Clamp Bolts9.6 N·m9.6 N·mp. 144
Clamp Bolts20.3 N·m15 ft·lbp. 144
Master Cylinder Mounting Clamp9.6 N·m9.6 N·mp. 144
Brake line20 N·mp. 148
Front hub castle nut54.2 N·m54 N·mp. 151
Mounting bolts20.3 N·m15 ft·lbp. 154
Brake caliper20.3 N·m15 ft·lbp. 155
Brake Caliper Mounting Bolt24.4 N·m24 N·mp. 155
Mounting bolt44.7 N·m45 N·mp. 158
O-Ring Starter Motor9.5 N·m7 ft·lbp. 179
Opposite engine case15 N·mp. 189
Engine locking screw10 N·mp. 197
Locking lever and spring6 N·mp. 238
Copper seal ring10 N·mp. 245
HH collar screws for clutch cover10 N·mp. 270
HH collar screws for ignition cover10 N·mp. 270
Oil drain plug20 N·mp. 270
HH plug for long oil screen15 N·mp. 270
HH collar screw for oil filter cover6 N·mp. 270
AH plug for bypass valve20 N·mp. 270
HH collar screws for cylinder head top section10 N·mp. 270
AH screws for end cap rocker arm shaft6 N·mp. 270
Couternut for valve adjusting screw11 N·mp. 270
HH collar screws for chain tensioner10 N·mp. 270
HH collar nut for rotor60 N·mp. 270
Spark plug17 N·mp. 270
AH bearing bolt for starter10 N·mp. 270

Spark plugs

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Spark plug0.6 mmp. 265
M10—p. 270

Service intervals

Values extracted from the document text. Check against the original before service work.

ItemValueAlsoPDF page
Coolant change2 yearsp. 16
Brake inspection2 yearsp. 20

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