I recently purchased a 2006 Polaris Outlaw 500. It had been sitting for 3 years, after about 10 minutes of trying to pull start it, it fired right up but would not idle. The previous owner said either going over the carb for a good cleaning or a rebuild would probably sort right out. When I got it home I pull started it again and after a bit of driving and warming the engine up it would idle and start up fine. After letting it cool it would not start again. I ordered an all ***** carb rebuild kit, cleaned out the carb, and rebuilt it. Put it all together and it will not fire. I checked everything i could think of but I am at a loss. I don't know if I should go over the carb again or what. Any help would be appreciated.

 

If you have spark(plus change the plug if you haven't already) sounds like you need to go back and recheck what you've done. Plus valve clearance needs to be checked/adjusted every 15 hrs on this racing machine. Valves set at .005 intake and exhaust. Every orifice/opening needs to be blown out thoroughly and you should be able to see daylight through the jets. Look over this parts break down on the carb for reference.If you need a manual here's a cheap one for 5 bucks. 2006 Polaris Outlaw 500 Service Manual PDF Download P.S. And obviously a fresh tank of fuel..

 

Thank you for the quick response. I have replaced the plug and added fresh gas. I will go over the carb again, and do a better job hopefully. Is checking the valve clearance something a novice can do? This is the first quad I've had the privilege of working on.

 

Another thing that I noticed while taking the carb back apart, was the main jet that came with the kit is 150 and the one that was in it before is 145. I do not know how big of a difference this will make.

 

Jetting jump shouldn't be the reason for a no start condition. The manual shows how to lock the crank shaft down in tdc position with the crank lock bolt. Then you can adjust the valves.Well worth the 5 bucks if you plan on working on this atv yourself.

 

I bought the manual, I will go through and see if I can figure it out. The only other thing is something electrical, but hopefully that's not the case. Tracing wires makes my eyes go cross.