2006 Polaris Outlaw 500

Markblaster20

Member
May 14, 2020
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So I am back to the quad bikes again after having some time away from them.

Just picked up a 2006 Polaris Outlaw 500. Needs some work and plan to do some aftermarket parts and custom made parts. Needs new bulbs for head lights, A wire/plug on hand bars sorted out as its not plugged into anything and think its for the front brakes for the light, Spring on the rear brake pedal for rear light, 2 bolts on the exhaust heat shield need sorted as the heads are broken off and thread is still in nut.

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Designing skid plates up at moment for it. Will also be doing rear A arm skids and Rear skid under sprocket and brake disc.

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Got some parts so far for it. Still waiting on so more and still need to order more parts. :)

Needs a big clean and grease removed.
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Mounting hardware for the a arm skids. Same as I did the blaster a arm skids.
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1st bit of bling. Fuel cap.
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To replace the stock aluminium one that is a bit loose and are known for stripping out.
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They run hard? Seen them around but never rode one

Yeah scared me the 1st time on it lol. I love the ground clearance as where I ride quads with solid axles are not the best because the swing arms is always hitting things and also can get stick easy on height points in the middle of the rear. Honda also have a IRS rear end quad also. seen one up for sale the other week. Didn't even know about the model till i seen it. :)
 
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Started working on the rear skid plate. Still need to sort out the guard for the disc brake and chain at the sprocket. 2 holes are for getting to the nut and bolt on bottom of the rear drive housing / chain tensioner. need to get this thing a clean so much dirt and grease on it.

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Time to start designing up the rear arm skids. Also need to make a list of the bushed and bearings to get as most of them a stuffed. Last owner didn't know what lube was.

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Also been working on the last parts on the rear frame skid. Will be one bit of aluminium bent and a small weld on the angles. Been looking into how other company's do it.
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Spent some time today working on airbox for the quad. Bloody shock that the company can sell something that don't even mount properly. Had to move the mounting brackets 20mm up on the sides of the airbox to be able to get the seat to go on. Washers also to level it for now till I drill new holes.


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Working on the rear grab bar of the quad shortened it 35mm and cnc cut some notches in it to clear the rear fender.

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