Home

Polaris Outlaw 525 IRS User's Manual

1. 12 216 1 Idle Speed 124 Indicator Lights 52 ooo EDS 126 187 Key Switch 51 K T tti x ere 86 L Lights 52 53 127 132 Brake Light 132 Headlight Adjustment 128 Headlight Assembly 130 131 Headlights 53 Indicator Lights 52 M Maintenance Chart 97 107 Making Turns 79 Manual Shift 64 67 Master Cylinder 60 61 23 Oil Change Engine 110 117 Oil Level Engine 109 Oil Recommendations 108 Operator Restrictions 14 Operator Safety 14 49 P Parking 62 63 Parking on a Hill or Incline 89 Passenger Warning 11 Periodic Maintenance Chart 97 107 Polaris Products 188 Polishing i iii spi ees 180 Pre Ride Inspection 72 73 R 14 Reverse Lock Out Switch 66 Riding 12 13 S Safety Decals Age 16 Waming 10 Discretionary Warning 10 General Warning 9 No Passenger Warning 11 Sport ATV Warning 10 Tire Pressure Load Warning 11 Safety Training 15 Severe Use 97 Shift Pedal iiss eis sive 64 Shifting 65 Side
2. 133 Cab Removal Rear 135 Camber and 167 Carburetor 2 124 125 Carburetor Draining 125 Carburetor Jetting 126 Chain Tension 164 165 Choke cand 70 Cl animngs ios 177 179 Clothing a zs seo e epe 13 Clutch Fluid 55 Clutch Levers 152 oes tees bu 54 Clutch System Bleeding 156 157 Compression Damping Rear 176 Consumer Product Safety 22 Coolant Level Radiator 120 Coolant Level Recovery Bottle 119 Cooling System 118 121 Cooling System Bleeding 121 Driving Across Hillsides Driving Downhill Driving in Reverse Driving on Slippery Surfaces Driving Over Obstacles Driving Procedure Driving Through Water Driving Uphill Electronic Throttle Control Emission Control Systems Engine Idle Speed Equipment Modifications Eye Protection 215 INDEX F Fluid Brake 342i tus 60 61 Cl tch o Est 55 Foot Brake 58 Foot Brake Fluid Level 61 Fuel 68 Fuel Stabilizer 183 Fuel System 74 Fuel Tank Ls 68 Fuel Valve 69 G H GIOVeS cse eed eut 13 Hand 59 Hand Brake Fluid Level 61 Handlebar Adjustment 166 Headlight Adjustment 128 Headlight Assembly 130 131 Headlights 53
3. 27 Safety Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 28 Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways 29 Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly long pants
4. 63 Features and Controls Manual Shift Shift Pedal The gear shift pedal is located in front of the left hand footpeg One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence The pedal automatically returns to a horizontal position when released To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal one full stroke See page 65 NOTE To shift into reverse see page 66 WARNING Shifting without releasing the throttle and disengaging the clutch could cause loss of control or vehicle overturn Always release the throttle and fully squeeze the clutch lever while shifting gears 64 poe J v 17 A gt E 4 4 T AN S NA i Gh o 5 KG Downshift Features and Controls Manual Shift Shifting Gears NOTE Always allow a cold engine to warm up before shifting gears 1 When starting from a stopped position place the transmission in neutral 2 Squeeze and hold the brake lever NOTE Do not squeeze the throttle lever Squeeze the clutch lever to disengage the clutch Depress the gear shift pedal one full stroke to shift into first gear Release the brake lever Gradually squeeze the throttle lever while slowly releasing the clutch lever SOY Gree As engine speed RPM increases in first gear simult
5. Adjust gap to specification 190 Engine Turns Over Fails to Start Troubleshooting Possible Cause Solution No spark to spark plug Inspect clean and or replace spark plugs See your Polaris dealer Overuse of choke flooded engine Engage starter 2 times for 5 seconds each then restart If engine fails to start inspect clean and or replace spark plugs Low battery voltage Recharge battery to 12 8 VDC Ignition system or other mechanical failure See your Polaris dealer Throttle ETC switch not opening Adjust throttle freeplay The plug connection of the CDI unit pulse generator or ignition coil has oxidized Clean the plug connection and treat with contact spray 191 Troubleshooting Engine Doesn t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 192 Troubleshooting Engine Backfires Possible Cause Solution Weak
6. All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles Welcome We believe Polaris sets a standard of excellence for all utility and recreational vehicles man ufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing deliv ered right to your door Break In Period Pre Ride Inspection Table of Contents Emission Control Systems 95 Maintenance 97 Specifications 186 Polaris Products 188 Troubleshooting 190 202 Maintenance Log 211 Index eM TEE 215 Know Your Ve
7. 4 After driving through water dry the brakes by applying light pressure to the lever while moving until braking action is normal If you do not perform this pro cedure your brakes may be ineffective M aximum Depth 90 Operation Driving Through Water Avoid operating your ATV through deep or fast flowing water If the ATV is operated in deeper water than recommended it s critical to have it serviced as outlined in the mainte nance chart beginning on page 97 Engine oil and all grease fittings need special attention CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footpeg level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 142 Have the vehicle serviced by your dealer at the first opportunity 91 Operation Driving in Reverse Follow these guideline
8. Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and 30 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV 31 Safety Operator Safety A WARNING A WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 32 Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedul
9. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation 38 Operator Safety Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 25 39 Safety Operator Safety WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual beginning on page 82 Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees 25 Never climb hills with excessively slippery or loose surfaces d Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 40 Safety Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HA
10. Printed in USA WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance Visit us at www polarisindustries com POLRHRIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc Copyright 2007 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is expressly prohibited Printed in U S A 2008 Outlaw 525 IRS ATV Owner s Manual P N 9920972 2 Welcome Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Snowmobiles
11. WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Ifthe vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Keep your body weight uphill 2 Pullin the clutch lever and apply the front and rear brakes 3 When completely stopped shut off the engine Leaving the transmission in gear release the clutch lever and lock the parking brake 4 Dismount on the uphill side of the vehicle or on the left side if the vehicle is pointing straight uphill 5 Staying uphill of the ATV turn the handlebars full left 86 Turning Around on a Hill 6 7 Operation Reach across the handlebar and apply the front brakes to unlock the parking brake With the front brakes applied pull in the clutch lever Use the brakes to slowly allow the vehicle to roll around to your right until it s pointing across the hill or shghtly downward With the front brakes still applied release the clutch lever and lock the parking brake Remount from the uphill side keeping body weight uphill Pull in the clutch lever shift into neutral and restart the engine Release the parking brake and
12. experience 18 Never attempt jumps or other stunts Never tow or pull an object behind the AT V Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and sched ules outlined in your owner s manual Always keep both hands on the handle bars and both feet on the footpegs of the ATV during operation Always travel slowly and use extra cau tion when operating on unfamiliar terrain Be alert to changing terrain conditions Operator Safety Never operate on excessively rough slip pery or loose terrain Always follow proper turning procedures as described in this manual Practice turn ing at low speeds before attempting to turn at faster speeds Do not turn at exces sive speeds Always have the ATV inspected by an authorized Polaris dealer 1f it s been involved in an accident Never operate the on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Safety Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose sur faces Shift your weight uphill Never open the throttle suddenly or make sud den gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terra
13. fouled or defective spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Exhaust leak Inspect system for leaks see your Polaris dealer Incorrectly installed spark plug wire See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer 193 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspect clean and or replace spark plug Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Defective ignition system See your Polaris dealer Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC or replace Kinked or plugged fuel vent line Inspect and replace Old or non recommended fuel Replace with recommended fuel 194 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Incorrect idle adjustment Adjust idle speed or see your Polaris dealer Clogged idle jet Di
14. 46 Safety Operator Safety A WARNING A WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the ATV or carrying towing cargo WHAT CAN HAPPEN Overloading or carrying towing cargo can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never haul cargo or tow a load with this ATV Never exceed the stated load capacity for this ATV Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions 47 Safety Operator Safety WARNING WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possibl
15. Filter Systems 123 Maintenance Carburetor Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture Replace the jet needle and the needle Jet after every 180 hours of operation Idle Speed Carburetor idle adjustments affect engine starting behavior A proper idle speed of 1500 1600 RPM will result in easier starting If idle speed is unsatisfactory use the following procedure to make adjustments 1 Position the vehicle on a level surface 2 Lock the parking brake Place the transmission in neutral 3 Start the engine and allow it to idle for five min utes or until operating temperature is reached 4 Turn the idle adjusting wheel 1 until idle speed reaches 1500 1600 RPM NOTE f idle speed is unsatisfactory after performing this procedure see your Polaris dealer for information about jetting changes 124 Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 97 Always drain the bowl after exposure to wet conditions Perform this procedure when the engine is cool Turn the fuel valve off 2 Placea suitable container under the carburetor to collect drained fluid 3 Remove the hex plug 1 Allow fluids to drain Reinstall the hex plug securely 125 Maintenance Carburetor Jetting Carburetor re jetting can be performed to compensate for altitude an
16. Front A Arms 2 45 6M Inspect tighten fasteners grease also after washing ATV or driving in water Stabilizer Bar 3 45 6M Grease Rear Control Arm Needle 90 12M Disassemble clean inspect bearings Bearings 4 seals grease reassemble 104 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used in gallons liters Clutch springs 60 12M 104 400 Check spring length see dealer Cam chain tensioner 60 12M 104 400 Check ratchet teeth for wear Coolant system 90 12M 156 600 Pressure test system annually P Cooling system hoses 90 12M 156 600 Inspect Radiator 90 12M 156 600 Inspect clean external surface change coolant every 2 years Fuel system 90 12M 156 600 Check for leaks at tank cap lines fuel valve filter carburetor replace lines every two years E Cylinder and piston 90 156 600 Inspect measure replace as needed Piston pin circlip groove 90 156 600 Visual inspection for wear gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 105 Maintenance Periodic Maintenance Chart Item Maintenance Interval whichever comes firs
17. K NOM 2 Remove wire harness connector from the cab The connector is located under the left fender 3 Remove the fuel tank cover screws 2 4 Remove the four side panel screws 3 5 Gently pull the cab upward to disengage it from Maintenance the stand off Place the cab upside down on a soft protective surface to prevent scratching 133 Maintenance Side Panel Removal 1 Unlatch and remove the seat 2 Remove the front cab 3 Remove the screw securing the side panel 4 Remove the side panel 134 Maintenance Rear Cab Removal 1 2 3 Unlatch and remove the seat Remove the two lower bolts 1 on the rear fenders of the cab Remove the two bolts 2 washers and grommets 3 on the top of the cab Remove the cab 135 Maintenance Spark Plugs Refer to the specifications section beginning on page 186 for recommended spark plug type and gap CAUTION Using non recommended spark plugs may result in serious engine damage and may void your emission related warranty Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for
18. Operator Safety Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully Follow all operating procedures Never operate an ATV without proper instruction Take a training course Pur chasers of a new Polaris ATV and age eli gible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Safety Operator Safety Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the terrain visi bility and operating conditions and your
19. POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators with advanced skills and substantial experience should operate this ATV 25 Safety Operator Safety WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates this ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate this ATV Only operators with advanced skills and substantial experience should operate this ATV 26 Safety Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers
20. Panel Removal 134 Signal 16 Spark Arrestor Clean Out 139 141 Spark Plug Removal 138 Spark Plugs 136 138 Spring Preload 170 Spring Preload Front 171 Spring Preload Rear 175 Starting the Engine 75 TT S Steering Inspection 167 St rage eei TS 181 184 Suspension eem 168 171 Re ats koc beer 172 176 Suspension Set Up Front 7 scere 168 169 Rearend 172 173 Switches Engine Stop Switch 51 Main Key Switch 51 Reverse Lock Out Switch 66 Start 51 T Throttle Cable Freeplay 159 Throttle Lever 56 57 Throttle Lever Freeplay 158 T Tires Installation 153 Removal 152 Tread Depth 151 Wheel Hub Tightening 152 Toe Alignment 162 163 Transporting the ATV 185 Turning Around on a Hill 86 87 V Vehicle Immersion 142 144 Warranty Emissions 209 210 Washing the Vehicle 178 179 Wheel Hub Tightening 152 Wheel Installation 153 Wheel Removal 152 217
21. and recharge as needed to maintain a full charge Battery Removal Remove the front cab see page 133 Disconnect the hold down strap securing the battery in position Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift the battery out of the ATV por 146 Maintenance Battery Installation NOTE Always install a fully charged battery Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger Place the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Attach the hold down strap Reinstall the front cab Venify that cables are properly routed ON A Se py 147 Maintenance Battery Charging Sealed Battery On a sealed battery the sealing strip cannot be removed Use a voltmeter or multimeter to measure DC voltage A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery The battery may be recharged without removing it from the vehicle Use the remote charging ter minals under the right front cab NOTE The Polaris Battery Tender battery charger can be left connected during the storage period and will automatically charge the battery if the voltage drops below a
22. can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 59 Features and Controls Master Cylinder Brake Fluid Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm 1s not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 60 Features and Controls Master Cylinder Brake Fluid Check the brake fluid in the master cylinder before each ride If the fluid level is low add DOT 4 brake fluid only Do not overfill See page 188 for the part numbers of Polaris prod ucts NOTE When checking the fluid level the master cylinder cover must be level Hand Brake Fluid Level View
23. change yearly 156 Jet needle needle jet 180 24M Replace Brake fluid 180 24M Replace Spark arrestor 300 36M Clean out 139 Front rear wheel bearings 300 36M Inspect replace as needed Toe adjustment As required Inspect periodically adjust when 162 parts are replaced Headlight aim As required Adjust as needed 128 P Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 107 Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97 Polaris recommends the use of Polaris PS 4 PLUS Performance Synthetic 2W 50 4 cycle oil or a similar oil designed for use in 4 stroke manual clutch ATV and motorcycle applications See page 188 for the part numbers of Polaris products NOTE Do not use Polaris PS 4 Performance Synthetic Oil Always use 2W 50 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never mix oil brands NOTE Ifthe ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained C
24. inspection Allow components to cool before continuing 136 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incor rect carburetion adjustments 137 Maintenance Spark Plugs Spark Plug Removal 1 Access the spark plug at the right side of the engine 2 Using the spark plug socket and a wrench rotate counterclockwise to remove the spark plug 3 After reinstalling the spark plug torque to 14 ft Ibs 19 Nm 138 Maintenance Spark Arrestor Clean Out To remove accumulated carbon clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 97 WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform clean out immed
25. manual differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal becomes illegible or comes off BT g contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number 15 printed on the decal Discretionary General Sport ATV Warning Warning General Warning WARNING Improper ATV use can result in SEVERE INJURY OR DEATH Always use an approved helmet and protective gear Never use on public roads Never carry passengers Never use with drugs or alcohol NEVER operate without proper training or instruction atspeeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control Safety Decals ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 7172560 Safety Decals Age 16 Warning Discretionary Warning WARNING Neveroperate this ATV on HILLS steeper than Operating this ATV if you are under the age of 16 25 degrees 25 To prevent flipov
26. of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 82 Operation Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill 2 Avoid steep hills 25 maximum 3 Keep both feet on the footpegs 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 83 Operation Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual 84 Operation Driving Across Hillsides If you enter into a situation where sidehilling is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep ing your feet on the footpegs 3 Steer slightly into the hill to maintain direction NOTE Ifthe vehicle begins to tip quickly turn the front wheels downhill if possible or dismount on the uphill side immediately 85 Operation Turning Around on a Hill
27. operate See your Polaris dealer Check boots for tears punctures and grease leaks 154 Rear shaft assembly 73 Operation Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked See page 69 Make sure the vent line is in good condition and is routed properly 74 Operation Starting the Engine The engine can be started when the transmission is in neutral or while in gear if the clutch is disengaged If starting a warm engine do not use the choke NOTE Fuel is injected into the intake passage each time the throttle lever is depressed Do not depress the throttle lever while starting the engine Do not depress the throttle lever when the engine is stopped WARNING Engine exhaust contains poisonous carbon monoxide
28. should contact the Polaris War ranty Department at 1 888 704 5290 210 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 3 Hours Break in 15 30 45 211 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL HOURS 60 90 212 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 213 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL HOURS 214 Age Restrictions 14 Air Filter Systems 122 123 B Battery Charging 148 150 Installation 147 Maintenance 145 Removal 146 Storage 146 181 Bleeding the Cooling System 121 bash ME 13 Brake Fluid 60 61 Brake Light Adjustment 132 Brake Maintenance 160 161 Brakes Foot 58 Hand Brake 59 Parking Brake 62 63 Break in Period 70 71 C Cab Removal Front
29. was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the sell ing dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 207 Warranty EXPORTED VEHICLES How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic war
30. 2008 POLARIS Outlaw 525 IRS Maintenance and Safety ic The Way Out This Category S Sport ATV is a high performance ATV for off road use only It is for sport type recreational and competitive use by operators with advanced skills and substantial experience Operation is prohibited for anyone under 16 years of age Read this manual carefully It contains important safety information AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL POLARIS The Way Out NEVER e Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle Operate at speeds too fast for your skills or conditions e Use ALCOHOL or DRUGS before or while operating this vehicle Carry Passengers ALWAYS Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills on rough terrain and in turns e Wear eye protection helmet and protective apparel For your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9920972 Rev 01
31. ATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 204 Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oll 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty Spark Arrestor Polaris warrants that the spark arrestor in this vehicle
32. D POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV Always maintain proper tire pressure as described in the owner s manual and on safety decals 45 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 90 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads
33. ZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 88 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 41 Safety Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 86 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 42 Safety Operator Safety WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward
34. aintenance Tires WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly DA tires will affect vehicle handling and could cause an accident resulting in serious injury or Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth i Always replace tires when tread depth is 1 8 8 mm worn to 1 8 3 mm or less 151 Maintenance Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance Bolt Location amp Size Torque Specification Front 3 8 30 35 ft Ibs 40 47 Nm Rear 3 8 30 35 ft Ibs 40 47 Nm Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine Place the transmission in gear Lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the frame 4 Remove the wheel nuts and remove the wheel Maintenance Wheel Installation WARNING Improperly installed wheels can adversely affect
35. and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the ATV immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 75 Operation Starting the Engine Oyen e bar 76 Shift the transmission to neutral Lock the parking brake Turn the fuel valve on Sit on the vehicle Disengage the clutch If the engine is cold pull the choke knob out until it stops Do not use the choke if starting a warm engine Move the engine stop switch to the RUN position Turn the ignition key to ON Choke Knob REESE gt Operation Starting the Engine NOTE If starting the engine while in gear apply the hand brake and squeeze the clutch lever fully to disengage the clutch If starting the engine while in neutral the neutral indicator light should be on If it isn t disengage the clutch and shift the foot pedal to find neutral See page 64 9 Press the start button to start the engine Activate the starter for a maximum of five sec onds Release the start button immediately when the engine starts NOTE Fuel is injected into the intake passage each time the throttle lever is depressed Do not depress the throttle lever while starting the engine Do not depress the throttle lever when the engine is stopped NOTE Excessive engagement may result in starter dama
36. aneously release the throttle disen gage the clutch and shift to second gear by raising the gear shift pedal one full stroke Repeat this procedure to progressively upshift to additional gears 8 Use the same procedure to downshift 65 Features and Controls Manual Shift Reverse Lock Out Switch The reverse lock out switch prevents the operator from shifting into reverse unintentionally 1 Place the transmission in first gear See page 64 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into reverse gear NOTE The lock will automatically re engage when the transmission is shifted out of reverse gear 66 Lock Out Lever Features and Controls Manual Shift Deceleration To slow or stop the vehicle release the throttle lever and apply the brakes smoothly and evenly As the vehicle slows and engine RPM decreases disengage the clutch and shift to a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear WARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tires to lose traction or stop rotating which could lead to loss of control accident and injury It could also cause engine or drive train damage Make sure the engine RPM has sufficiently decreased before shifting to a lower gear 67 Features and Controls Choke The choke assists in starting a co
37. ble Freeplay Adjustment WARNING Improper adjustment of throttle cable freeplay can result in loss of control which could result in serious injury or death Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it s done correctly Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly 1 Locate the throttle cable at the handlebar Locking Nut 2 Slide the boots off the inline cable adjuster Sleeve sleeve and loosen the locking nut 3 Tum the adjuster until 1 16 to 1 8 1 5 3 mm freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the Boot Boot throttle lever back and forth 4 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 159 Maintenance Brakes WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill Both brakes are self adjusting but the following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under nor mal operation 160 Maintenance Brakes 1 Always maintain brake fluid at the recommended level See pages 60 61 Check the brake system for fluid leaks Check the brakes for excessive t
38. cated in front of the right hand footpeg If the rear wheels slide while using the foot brake reduce brake pedal pressure to brake the wheels without skidding Check the brake fluid level frequently for the foot brake system The reservoir is located under the seat Maintain the fluid level between the minimum and maximum marks Check the rear brake light for proper operation before each use of the vehicle See page 132 WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the foot brake Do not aggressively apply the foot brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death Foot Brake 58 Features and Controls Hand Brake The hand brake operates the front brakes The hand brake 15 located on the right handlebar Squeeze the brake lever toward the handlebar to engage the front brakes These brakes are hydraulically activated disc type brakes Always test brake lever travel and master cylin SS der fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylin der fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Hand Brake WARNING Operating the ATV with a spongy brake lever
39. contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation The throttle lever is located on the right handlebar Squeeze the lever toward the handlebar to increase engine speed and vehicle movement Engine speed returns to idle when the lever 1s released See page 159 for throttle adjustment procedures NOTE Fuelis injected into the intake passage each time throttle is applied Do not squeeze the throttle lever Throttle Lever while starting the engine Do not squeeze the throttle lever when the engine is stopped 56 Features and Controls Throttle Lever This ATV is equipped with an Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open posi tion when the operator releases the throttle lever the engine will stop WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanism 57 Features and Controls Foot Brake The foot brake operates the rear brakes The brake pedal is lo
40. d Owner s Manual for more detailed loading information 7174881 11 Safety Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be dis played on the label 12 Long Helmet Sleeves Long Pants 051039 0006 31 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of strong over the calf boots with low heels Clothing Always wear long sl
41. d by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGIS TERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 202 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This war ranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages
42. d dealer perform these operations 98 Maintenance Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a lil could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Maintenance Chart Key E Perform these operations more often under severe use Emission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 99 Maintenance Periodic Maintenance Chart Item Maintenance Interval whichever comes first Hours Calendar Fuel Used Remarks See Page Brake systems brake fluid Tires Wheels lug nuts Frame fasteners Coolant Pre ride Fuel Engine oil Transmission oil Throttle Clutch system clutch fluid Lights Engine stop switch Steering Check each day before operating the vehicle Make adjustments as needed See the Pre Ride Checklist 72 100 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page in gall
43. d or temperature changes If the vehicle 1s to be operated at various altitudes and temperatures certain adjust ments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 396 of its power for each 1000 foot 305 m increase in elevation Although this power cannot be regained changes to the carburetor and drive system can be made to allow more efficient operation NOTE Contact your dealer for altitude adjustments Your dealer has the training and special tools required to perform these modifications 126 Maintenance Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently 127 Maintenance Lights Headlight Adjustment 1 Position the vehicle on a level surface with the head light approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the
44. dlight Assembly Replacement 6 Install the adjuster bracket onto the inboard pivot pin of the headlamp Adjust for approximately 1 16 clearance between the bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket 15 90 degrees to the pivot pin so the lamp can move freely Install the adjusting screw leaving it loose so the headlight can be adjusted Reinstall the front cab Connect the wire harness to the headlamp Adjust the lamps as needed see page 128 then tighten the adjuster screw 131 Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of vehicle Switch 1 Turn the ignition key on 2 Lightly apply and release the foot brake several times Adjustment A properly operating rear brake light will immedi Nut ately flash on and off with each movement of the brake pedal 3 Ifthe light does not operate properly grasp the switch body with a pliers or similar tool and hold it lightly but securely Using a wrench rotate the adjustment nut clockwise to increase tension on the spring NOTE Rotate the adjusting nut counter clockwise to decrease tension on the spring if the brake light comes on when there is no pressure on the brake pedal 4 Recheck and readjust as needed until the brake light operates properly Spring 132 Front Cab Removal o p 1 Remove the left and right cab mount screws 1
45. ds on the handlebars 168 Maintenance Front Suspension Suspension Set Up 6 7 8 Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet 3 m without lifting or pushing down on the suspension Turn the handlebars fully to the left and right With the rider still on the vehicle repeat the measurement performed in step 4 Subtract the step 8 measurement from the step 4 measurement The difference should be between 3 75 and 4 inches 9 5 10 2 cm If the number is less than 3 75 inches 9 5 cm decrease the front spring preload see page 170 and repeat all steps If the number is higher than 4 inches 10 2 cm increase spring preload and repeat all steps 169 Maintenance Front Suspension Spring Preload The pone suspension preload may be adjusted to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments 170 Front Suspension Spring Preload 1 Raise and safely support the front ofthe vehicle off the ground to allow the suspension to fully extend Loosen the jam nut Turn the adjusting ring clockwise to increase preload 1 Turn the ring counter clockwise to decrease preload 2 Tighten the jam nu
46. e damage including but not limited to brakes throttle and steering systems 48 Operator Safety Safety WARNING WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 49 Features and Controls Main Key Switch Engine Stop Switch Start Buton Features and Controls Main Key Switch The main key switch must be in the RUN position to start the engine See page 75 for starting procedures Start Button Press the start button to engage the starter Always release the start button promptly when the engine starts NOTE Ifthe starter fails to engage replace the blown fuse or see your Polaris dealer Engine Stop Switch lt gt Move the stop switch either left or right to the OFF ar rJ position to stop the engine quickly The engine will g not start or run when the switch is off NOTE Both the main switch and the engine stop switch OFF RUN OFF will shut off all electrical power to the vehicle including lights 51 Features and Controls Ligh
47. e handle bar Turn the adjusting knob clockwise to move the lever away from the handlebar NOTE The adjustment range is limited Never apply excessive force to the knob Always turn the knob manually Always check the lever for smooth operation before riding If the lever does not operate smoothly check the fluid level at the master cylinder See page 55 If the lever begins to feel unresponsive bleed the clutch system as outlined on page 156 54 Features and Controls Clutch Fluid The clutch fluid master cylinder is located on the S left handlebar Check the fluid level in the reservoir CIENS before each ride The level should be 4mm below the upper edge of the reservoir Do not overfill Polaris recommends the use of KTM Hydraulic Clutch Oil Do not use brake fluid Do not mix clutch fluid with any other hydraulic fluids See page 188 for the part numbers of Polaris products 1 Position the vehicle on a level surface 2 Turn the handlebar until the master cylinder is in a horizontal position 3 Remove the two cover screws the cover and the rubber boot 4 Add the recommended fluid as needed 5 Reinstall the cover boot and screws securely 55 Features and Controls Throttle Lever WARNING Operating with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate the vehicle with an improperly operating throttle Always
48. e of the vehicle under the front fender The fluid level must be maintained between the FULL and ADD marks on the side panel when the fluid is cool As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle 119 Maintenance Engine Cooling System WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the cap Radiator Coolant Level Pressure Cap f If the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary The radiator pressure cap is located on the left side of the vehicle 1 Remove the pressure cap 2 Using a funnel slowly add coolant as necessary through the radiator filler neck 3 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 120 Maintenance Engine Cooling S
49. e spark plug start the engine and move the ATV promptly to a trailer or towing vehicle CAUTION If water isn t removed promptly from a submerged ATV rust will form in precision components gears bearings the cylinder and other areas and result in serious engine damage Always see your dealer promptly after an ATV has been submerged 144 Maintenance Battery The sealed battery 15 already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 145 Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage
50. e speed below 75 of capacity No single action on your part is as important as following the procedures for a proper break in Perform the following break in and maintenance procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not allow engine speed to exceed 7000 RPM during the first three hours of use Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 70 Break In Period 1 Fill the fuel tank with gasoline See page 74 2 Check the oil level Add the recommended oil as needed to maintain the oil level in the proper range See page 109 3 Allow the engine sufficient time to warm up before operating Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 5 Vary throttle positions Do not operate at sustained idle 6 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 72 7 Atthe end of the break in period 3 hours change the engine oil and the long and short oil filters See page 110 Clean the oil screen and drain plug magnet CAUTION Failure to perform the recommended break in maintenance procedures can result in serious engine damage Change the oil and filters after the first three hours of
51. eeves and long pants to protect arms and legs Riding pants with knee pads and a Jersey with shoulder pads provide the best protection Safety Operator Safety WARNING Failure to follow the warnings in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand the owner s manual and all warnings before operating a Polaris ATV Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road use only for sport type recreation and for competitive use by operators with advanced skills and substantial experience 14 Operator Safety Safety Training safety training is a top priority for Polaris When you purchased your new AT V your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training 1s included in the purchase price of your ATV Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCourse You were also pro
52. er of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires spray ers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 23 Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourse contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org 24 Safety Operator Safety WARNING
53. er on increases your chance of severe injury or death hilly terrain use throttle and brakes gradually NEVER operate this ATV if you are under age REVERSE operation can be dangerous even 16 at low speeds Steering becomes difficult To 7172559 prevent flipover avoid sudden braking or Sport ATV Warning PARKING BRAKE may relax when used for WARNING more than 5 minutes When parking on This ATV may exceed the performance of other grades leave ATV in gear ATVs you may have ridden in the past This 7173837 category S Sport ATV is a high performance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience 7173837 10 No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7172566 Tire Pressure Warning Safety Decals Tire Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 4 27 6 MAXIMUM WEIGHT CAPACITY 215 LBS 97 5 KG INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control For stability on rough or hilly terrain reduce speed and cargo Rea
54. es described in the Owner s Manual Safety Operator Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other stunts Avoid exhibition driving 33 Safety Operator Safety WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV WHAT CAN HAPPEN A wagon sled or other object towed behind an ATV does not have brakes or steering The object may overturn or collide with other objects and cause serious injuries HOW TO AVOID THE HAZARD Never tow or pull an object behind the ATV 34 Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 35 Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could
55. ge 10 Ifthe engine does not start wait five seconds after releasing the start button then acti vate the starter for another five seconds Repeat until the engine starts NOTE Ifthe engine does not start review the engine troubleshooting information beginning on page 190 If all conditions are favorable and the engine still does not start see your Polaris dealer for service 11 Push the choke knob completely in 12 Vary engine speed slightly with the throttle to aid in warm up 77 Operation Driving Procedure 1 Sit upright with both feet on the footpegs and both hands on the handlebars 2 Startthe engine and allow it to warm up 3 Shiftthe transmission into gear See page 64 4 Check your surroundings and determine your path of travel 5 Release the parking brake 6 Slowly depress the throttle with your right thumb while slowly releasing the clutch lever to begin driving 7 Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces 78 Operation Making Turns Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury or death Avoid turning at sharp angles Never turn at high speeds Your 15 equipped with a solid rear axle which drives both rear wheels equally at all times The wheel on the outside
56. hange the oil immediately if the oil level rises 108 Maintenance Engine Oil Level Sight Glass Check the oil level before each use of the vehicle Ifthe engine is cold the oil level should be visible at the lower edge of the sight glass If the engine is warm the oil level should be visible at the center of the sight glass A high oil level can cause engine overheating which could result in engine damage Always maintain the oil level as recommended 1 Position the vehicle on a level surface 2 View the oil level through the sight glass on the right side of the vehicle 3 Remove the fill plug and add the recom mended oil as needed 4 Reinstall the fill plug Fill Plug Warm Level Cold Level 109 Maintenance Engine Oil Change CAUTION If the ATV is left without oil in the system for extended periods the oil pump may lose its prime which could result in engine damage Do not allow the vehicle to be without oil and filter overnight Always replace the oil and filters within a few hours of draining the oil Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97 Perform the initial break in oil change after the first three hours of operation Always change both oil filters and clean the oil screens whenever changing oil NOTE Change the oil more frequently on vehicles subjected to severe use 110 Engine Oil Change 1 Position the veh
57. headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 5 cm below the mark placed on the wall NOTE Include rider weight on the seat when measuring Pivot Screw 5 Loosen the pivot screw and adjust the beam to the desired position 6 Tighten the screw and torque to 27 in lbs 3 Nm 128 Maintenance Lights Headlight Lamp Replacement Remove the wire harness connector from Left Lam Right Lamp the back of the headlight Ai Clockwise 2 Onthe left headlamp grasp the bulb housing and turn it counterclockwise to remove the bulb On the right headlamp turn the bulb housing clockwise to remove the bulb 3 Apply dielectric grease to the socket and install the new bulb Rotate firmly NOTE The bulb must be positioned so the harness installs into the lamp at outer side 4 Reinstall the connector to the back of the headlight 129 Maintenance Lights Headlight Assembly Replacement 1 2 3 130 Remove the wire harness connector from the P headlights ay Remove the front cab see page 133 Remove the small adjuster bracket Install it on the new lamp Remove the large pivot bracket and remove the headlamp Install the new headlamp by inserting the outboard pivot pin in the hole of the mounting tab on the cab Large Pivot Bracket Small Adjuster Bracket Maintenance Lights Hea
58. hicle The high performance engine in your vehicle requires routine service to maintain the highest level of performance and reliability Please read and follow the Break In Period and Maintenance sections of your Owner s Manual carefully Failure to perform the recom mended procedures at the service intervals specified in your owner s manual will void war ranty coverage and decrease the performance and reliability of your vehicle As the operator of the vehicle you are responsible for your personal safety the safety of oth ers and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating pro cedures Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Identification Numbers Vehicle Model Number Frame Vehicle Identification Number 1 Engine Serial Number 2 Key Number on the key Know Your Vehicle Safety Decals Warning decals have been placed on the vehicle for your protection Read and follow the instructions on each decal carefully If any of the decals shown in this
59. iately after the engine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Allow components to cool sufficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time 139 Maintenance Spark Arrestor Clean Out NOTE Refer to the illustration on page 141 1 Remove the retaining screw and remove the arrestor from the end of the muffler 2 Use anon synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm NOTE If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Replace a worn or damaged screen 4 Reinstall the arrestor Torque the screw to 5 7 ft lbs 7 9 Nm 140 Maintenance Spark Arrestor Clean Out Arrestor Muffler Retaining Screw 141 Maintenance Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level it s critical to dry it promptly and properly before starting the engine CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended depth Serious engine damage WILL occur Tow or trailer the ATV to your dealer for service In an emergency perform the temporary drying out procedure outlined below
60. icle on a level surface NOTE Remove the skid plate for better access to the oil drain plug and short screen 2 Startthe engine Allow it to idle for two to three minutes Stop the engine 3 Place a drain pan beneath the crankcase Remove the drain plug Allow the oil to drain completely A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin Maintenance Drain Plug 4 Clean the crankcase sealing surface and the drain plug with magnet thoroughly 5 Replace the sealing ring Reinstall the drain plug Torque to 15 ft Ibs 20 Nm 111 Maintenance Engine Oil Change Cleaning the Short Oil Screen NOTE Remove the skid plate for better access to the oil drain plug and short screen View from bottom of vehicle 112 Maintenance Engine Oil Change Cleaning the Short Oil Screen l 2 3 Remove the plug at the bottom of the engine See illustration on preceding page Remove the short oil screen from the plug Clean the screen components thoroughly and blow well with compressed air Check the O rings If damaged install new O rings Reinstall the screen to the plug Lubricate the threads and reinstall the plug Torque to 7 5 ft Ibs 10 Nm 113 Maintenance Engine Oil Change Cleaning the Long Oil Screen 1 Remove the long screen plug located on the side of the engine near the engine number 2 Remove the oil screen Clean the screen thor
61. in carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Safety Operator Safety Always follow proper procedures for Always use proper procedures if you stall crossing the side of a hill Avoid hills with excessively slippery or loose sur faces Shift your weight uphill Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special procedure for braking described in this manual Always dismount on the uphill side or to either side if the is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Operator Safety Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of con trol Always check for obstacles before oper ating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Safet
62. ld engine The choke knob is located on the left side of the carburetor Refer to the engine starting procedure on page 75 for correct choke and throttle settings during starting Fuel Tank The fuel tank filler cap is located directly below the handlebar Polaris recommends the use of 91 octane or higher fuel Do not use E 85 fuel Fuel Filter The fuel valve has an internal fuel filter Do not attempt to clean the fuel filter See your Polaris dealer for ser vice if you suspect the fuel filter is plugged 68 Choke Knob ENSE gt Features and Controls Fuel Valve The fuel valve is located on the left side of the ATV It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling 69 Break In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both The break in period for your new Polaris ATV is the first three hours of operation or the time it takes to use 5 6 gallons 20 liters of fuel Do not allow engine speed to exceed 7000 RPM during the break in period Follow the break in period with an additional 12 hours of cautious operation with engin
63. ntact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 179 Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Pin the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 180 Maintenance Storage CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Exterior Make necessary repairs and clean the vehicle as recommended See page 177 Battery Storage Refer to pages 145 150 for battery storage and battery charging procedures 181 Maintenance Storage Engine Oil Change the oil and both filters Clean the oil screens See page 110 Air Filter Air Box Inspect and clean or replace the air filter Clean the air box Drain the sediment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 97 Transmission Oil Engine Oil e C
64. ntrol and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 3 Torque the two front bolts to 10 12 ft 165 14 16 Nm then torque the two rear bolts NOTE A gap of up to 1 8 3 mm will remain at the rear bolts 4 Check sprocket bolt torque Torque to 30 ft 165 40 Nm 166 Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts If loose nuts and bolts are found or if you notice any freeplay the steering post see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable 167 Maintenance Front Suspension Suspension Set Up 1 Position the vehicle on a level surface 2 Stop the engine 3 Elevate the front of the vehicle by placing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the lower front bumper bolt Note this measurement for later use 5 Remove the stand and have a rider sit comfortably on the seat with han
65. of the turn travels a greater distance than the inside wheel when turning and the inside tire slips traction shghtly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse 79 Operation Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution especially when downshifting 80 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 81 Operation Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss
66. oke 95 x 72 mm Lubrication System Dry Sump Internal Reservoir 186 Specifications Outlaw 525 IRS Driving System Type Rear Two Wheel Drive Tire Size Front 21 x 7R10 Shift Type 5 Speed Manual Shift Tire Size Rear 20 x 10R9 Primary Ratio 2 516 Tire Pressure All 4 psi 27 6 KPa Gear Ratio 1st 2 500 Front Brake Hydraulic Disc Dual Bore Gear Ratio 2nd 1 941 Rear Brake Hydraulic Disc Gear Ratio 3rd 1 579 Parking Brake Hydraulic lock front wheel Gear Ratio 4th 1 333 Headlights 2 Dual Beam 35w 35w Gear Ratio 5th 1 130 Taillights LED Gear Ratio Reverse 2 429 Brakelight 26 9w Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F Below 5 C 40 and above 5 and above 0 1800 0 6000 Main Jet 158 Main Jet 148 Needle Clip Position 4 Needle Clip Position 4 1800 3700 6000 12000 Main Jet 148 Needle Clip Position 43 Needle Clip Position 43 Main Jet 138 187 Polaris Products Part Number Description Engine Lubricant 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium Season Grease 3 oz cartridge 2871423 Premium Season Grease 14 o
67. onents CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle 177 Maintenance Cleaning Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 178 Maintenance Cleaning Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the following items Wheel bearings Brakes Electrical components and wiring Cab and body panels Transmission seals Labels and decals NOTE If warning and safety labels are damaged co
68. ons liters Air box sediment tubes Pre ride Check each day before operating 72 Headlamp the vehicle Make adjustments as _ needed See the Pre Ride Check Tail lamp brake lamp list A arm ball joint Rear shaft assembly Boots Post ride Burp boots if bulging ballooned 155 Oil and filter change Change the oil and filters 110 Oil screen drain plug 3 Break in 5 20 Clean screen and plug magnet 112 Idle speed Check idle speed setting 124 Engine mounting bolts Check torque Valve clearance Check adjust enmy Perform these procedures more often for vehicles subjected to severe use Emission Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 101 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page in gallons liters Brake pad wear 10 Monthly Inspect regularly 161 Rear sprocket bolts 10 Monthly Check torque 166 Battery 10 Monthly Check terminals clean test 145 PE Air filter 15 Weekly Inspect clean replace as needed 122 gt Oil and filter change 15 6M 26 100 Perform initial oil change after first 110 3 hours of operation Oil screen drain plug 15 6M 26 100 Clean screen and plug magnet 112 Idle speed 15 6M 26 100 Check adjust as needed 124 Engine moun
69. oolant test strength fill Brake Fluid Clutch Fluid 182 Maintenance Storage Stabilize the Fuel 1 Fill the fuel tank with fuel 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems It also prevents bacterial growth and pro motes better starting after the storage period 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor Stop the engine Turn the fuel valve off Start the engine Allow the engine to operate until it stops Drain the carburetor bowl See page 125 Remove the spark plug Pour approximately 5 cc of engine oil into the cylinder through the opening Using the start button rotate the engine several times to distribute the oil onto the cylinder walls Reinstall the spark plug Torque to specification w 183 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 97 Storage Area Covers 1 Make sure tire pressure is at specification 2 Be sure the storage area is well ventilated 3 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching
70. oot 4 Reinstall the boot clamp 155 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out lined in the Periodic Maintenance Chart beginning on page 97 Always bleed the clutch system any time the clutch lever feels unresponsive Always use the recommended fluid when bleeding the clutch system See page 55 1 Position the vehicle on a level surface Turn the handlebar until the master cylinder is in a hori zontal position 2 Remove the two cover screws the cover and the rubber boot 3 Filla bleeder syringe 1 with the recommended hydraulic clutch oil 156 Maintenance Clutch System Bleeding 4 i Remove the bleeder screw 2 from the slave cylinder Press fluid into the system until the fluid runs out of the hole 3 in the master cylinder without producing bubbles NOTE Extract fluid from the master cylinder during the process to prevent overflowing 6 7 8 When finished remove the bleeder syringe Reinstall the bleeder screw Add or remove fluid as needed to maintain the level 4mm below the top edge of the mas ter cylinder reservoir Reinstall the cover boot and screws securely 157 Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay Maintain freeplay between 1 16 and 1 8 1 5 3 mm If adjustments are needed use the procedure on page 159 ne 1 8 1 5 3 mm 158 Maintenance Throttle Ca
71. operation 71 Pre Ride Inspection A WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the vehicle before each use to ensure it s in proper operating condition Pre Ride Checklist Page Brake systems lever travel Ensure proper operation 58 63 160 161 Brake fluid Ensure proper level 60 Clutch lever Check for proper operation and adjustment 54 Clutch fluid Ensure proper level 55 Suspension front and rear Inspect lubricate if necessary 104 Steering Check for free operation loose components Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 68 109 72 Pre Ride Inspection Pre Ride Checklist Page Coolant if applicable Ensure proper level 119 Coolant hoses if applicable Inspect for leaks Throttle Ensure smooth operation 56 Indicator lights switches Ensure operation 52 53 Engine stop switch Ensure proper operation 51 Air filter Inspect clean replace as needed 122 Air box sediment tubes Drain deposits when visible Headlamp Check operation apply Polaris dielectric grease to 129 the socket when the lamp is replaced Brake light tail lamp Check operation adjust brake light switch 132 Riding gear Wear helmet goggles protective clothing 12 A arm ball joints Check freeplay If the tire moves excessively do not
72. oughly and blow with compressed air 3 Check the O rings If damaged install new O rings 4 Place the long oil screen on a pin type key or similar tool of about 12 inches 300 mm in length 114 Maintenance Engine Oil Change Cleaning the Long Oil Screen CAUTION An improperly installed oil screen will function poorly and result in increased engine wear Install the screen securely at the angle shown in the illustration 2 2000 A See al HN T7 7 AT DELL AL 5 Insert the tool through the opening and into the bore of the opposite engine casing wall Push the oil screen into the casing as far as possible Remove the tool 6 Reinstall the plug Torque to 11 ft 165 15 Nm 115 Maintenance Engine Oil Change Changing Oil Filters 1 Place a drain pan under the engine 2 Remove the four oil filter cover screws 1 Remove the covers 3 Usingcircle clip snap ring pliers pull the oil filter inserts 2 out of the housing 4 Thoroughly clean the engine casing filter covers and sealing surfaces of the O rings Check the O rings If damaged install new O rings 5 Filleach oil filter with oil Install the long filter at the front of the filter box Install the short filter at the rear of the box 116 Maintenance Engine Oil Change Changing Oil Filters 6 7 8 10 11 Grease the filter cover O rings 3 Reinstall the c
73. overs and the screws Tighten screws to 4 5 ft Ibs 6 Nm Remove the oil fill plug 4 Add 1 7 qts 1 6 1 of the recommended engine oil see page 108 Reinstall the fill plug Start the engine Allow it to idle for at least one minute to fully distribute the new oil Stop the engine Check for leaks at all threaded connections and at the oil filter covers View the oil level in the sight glass Add oil as needed to maintain the level as recommended see page 109 117 Maintenance Engine Cooling System The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle radiator filler neck radiator pressure cap and connecting hose To ensure that the coolant maintains its ability to protect the engine we recommend that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water See page 188 for the part numbers of Polaris products NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area 118 Maintenance Engine Cooling System Coolant Level The recovery bottle 15 located on the right sid
74. pre determined point NOTE Ifthe battery fails to recharge during vehicle operation check voltage regulator connec tions See your Polaris dealer for inspection of the voltage regulator and generator Charging Terminal 148 Maintenance Battery Charging Sealed Battery When using an automatic charger such as the Polaris Battery Tender refer to the manufac turer s instructions for recharging When using a constant current charger use the guidelines on the following page for recharging WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 149 Maintenance Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging Charge Time State of Voltage Action Using constant current Charge charger standard amps specified on top of battery 10096 12 8 13 0 volts None check at 3 months from None required date of manufacture 7596 10096 12 5 12 8 volts May need slight charge if no 3 6 hours charge given check in 3 months 5096 7596 12 0 12 5 volts Needs charge 5 11 hours 2596 5096 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 096 2596 11 5 volts or less Needs charge with desulfating At least 20 hours charger 150 M
75. ranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 208 Warranty U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date after 5000 km 3100 miles or after 500 hours of operation whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance 209 Warranty U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive op
76. ravel or spongy feel Check the friction pads for wear damage and looseness Check the security and surface condition of the disc Inspect the rear brake disc spline and pad wear surface for excessive wear NOTE Pads should be changed when worn to 3 64 1 mm Qv cota 3 64 1 mm 161 Maintenance Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The vehicle is designed for a neutral toe setting 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position Use tie straps to secure the handlebars to the rear grab bar so they can t move 3 Place stands in front of the vehicle perpendicular to the rear tires See illustration 162 Maintenance Toe Alignment 4 Tiean elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 5 Measure the distance between the string in front of the rear tires 1 and in front of the front tires 2 If the two measurements are not equal adjust the string position until the mea surements are equal 6 Measure the distance from the string to the rim at
77. result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 36 Operator Safety Safety WARNING WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 37 Safety Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could contact the rear wheels and lead to accident or injury
78. rm Any other adjustments should be performed by an authorized Polaris dealer The compliance label is located on a frame tube to the left side of the frame behind the radi ator 96 Maintenance Periodic Maintenance Chart The high performance engine in your vehicle requires routine service to maintain the highest level of performance and reliability Please read and follow the Break In Period and Maintenance sections of your Owner s Manual carefully Failure to perform the recommended procedures at the service intervals specified in your owner s manual will void warranty coverage and decrease the performance and reliability of your vehicle Recommended service intervals are based on average riding conditions Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Shorttrip cold weather operation 97 Maintenance Periodic Maintenance Chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 211 NOTE Service and adjustments are critical If you re unable to perform the required service and adjustment procedures have a qualifie
79. s turned counter clockwise until it stops the damping is in the soft est position position 1 Turn the screw clockwise to increase damping NOTE Use a flat blade screwdriver to make damping adjustments Rear Shock Setting Compression Damping Softest Position 1 Factory Position 4 Firmest Position 27 174 Rear Suspension The rear suspension spring preload shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the vehicle off the ground to allow the suspension to fully extend 2 Turn the adjusting ring clockwise 1 to increase preload Turn the ring counter clockwise 2 to decrease preload Maintenance Adjusting Ring 175 Maintenance Rear Suspension Compression Damping The compression damping clickers are located on the bottom of the shocks on the lower clevis Use a screwdriver to make adjustments To set the shock at the softest setting position 1 turn the screw counter clockwise until it stops From this position turn the screw clockwise to increase com pression damping Setting Compression Damping Softest Position 1 Factory Position 4 Firmest Position 7 Clicker 176 Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various comp
80. s when operating in reverse Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Always avoid backing downhill Never open the throttle suddenly while backing 6 Always look left right and behind the ATV before backing Gi 92 K A NN ON ASS lt 2 N a K 174 E NS ay Y e Operation Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle Follow the reverse operation procedures outlined in this manual This Polaris ATV is equipped with a reverse speed limiter Do not operate at full throttle Use just enough throttle to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 93 Operation Driving Over Obstacles Be alert Look ahead and learn to read the ter rain you re traveling on Be constantly alert for hazards such as logs rocks and low hang ing branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 94 Emission Control Systems Noise Emission Control System Do no
81. sassemble carburetor and clean the jets Other mechanical failure See your Polaris dealer 195 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Old or non recommended fuel Replace with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with recommended octane fuel Incorrect jetting See your Polaris dealer Plugged dirty or wet air filter Clean pre filter replace main filter as needed 196 Engine Fails to Reach High RPM Troubleshooting Possible Cause Solution Worn or dirty needle valve Clean and or replace needle valve Loose carburetor jets Tighten jets Faulty ignition timing See your Polaris dealer Engine Uses Excessive Oil Possible Cause Solution Bent engine ventilation hose Install a new hose Excessive oil in system Check oil level maintain at recommended level Use of non recommended oil too thin Replace with a recommended oil 197 Troubleshooting Engine Stops or Loses Po
82. slowly release the clutch lever allowing the ATV to pro ceed slowly Stay in first gear using the brakes for additional speed control if necessary until more level ground is reached Do not apply the brakes abruptly when driving down hill 87 Operation Driving Downhill Whenever descending a hill follow these precautions 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Shiftto the lowest gear possible while maintaining a safe speed 5 Apply the foot brake slightly to aid in slowing WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 88 Parking on a Hill or Incline Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Turn the fuel valve off Operation 89 Operation Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs Follow these proce dures when operating through water 1 Determine water depths and current before crossing 2 Choosea crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible
83. speed is lost Keep your weight uphill Apply the front brakes gradually right lever When fully stopped apply the foot brake as well and then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to either side if pointed straight uphill Use the K Turn to turn the ATV around and remount See page 86 43 Safety Operator Safety WARNING WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 44 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual Safety Operator Safety A WARNING A WARNING POTENTIAL HAZAR
84. t Remarks Hours Calendar Fuel Used in gallons liters E Compression ring 90 156 600 See your dealer or refer to the Dealer E Oil scraper ring 90 156 600 Service Manual measure ring gap and replace if at or below service limit Camshaft 90 156 600 Visual inspection for wear Valve spring cap 90 156 600 Visual inspection for wear E Camshaft bearings 90 156 600 Replace Valve springs 90 156 600 See your dealer or refer to the Dealer E Valve seats guides 90 156 600 Service Manual perform measurements replace as needed E Rocker arm rollers 90 156 600 E Timing chain 90 156 600 Measure elongation replace as needed Cam chain tensioner 90 156 600 Check ratchet teeth for wear E Bearings connecting rod 90 156 600 Replace balance shaft crankshaft main Crankshaft run out 90 156 600 Measure adjust as needed 106 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page in gallons liters Oil pressure valve 90 156 600 Measure spring replace as needed Transmission 90 156 600 Check entire transmission bearings for wear replace as needed WIE Ignition Timing 12M Inspect adjust as needed Clutch fluid 90 12M Bleed as needed
85. t against the adjusting ring Maintenance Jam Nut Eod 4 5 2 2 Adjusting gt Ring D 171 Maintenance Rear Suspension Suspension Set Up 1 Position the vehicle on a level surface 2 Stop the engine 3 Elevate the rear of the vehicle by plac ing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the rear lower control arm pivot bolt Note this measurement for later use 172 Maintenance Rear Suspension Suspension Set Up 5 6 7 8 10 Remove the stand and have a rider sit comfortably on the seat with hands on the handle bars Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet 3 m without lifting or pushing down on the suspension Turn the handlebars fully to the left and right With the rider still on the vehicle repeat the measurement performed in step 4 Subtract the step 8 measurement from the step 4 measurement The difference should be between 4 and 4 25 inches 10 2 10 8 cm If the number is less than 4 inches 10 2 cm decrease the rear spring preload on both shocks see page 175 and repeat all steps If the number is higher than 4 25 inches 10 8 cm increase spring preload and repeat all steps 173 Maintenance Rear Suspension When the adjuster screw i
86. t modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level require ments Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 1 c Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 95 Emission Control Systems Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be main tained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perfo
87. the fluid level through the indicator window on the side of the master cylinder Maintain the fluid level at or slightly above the mark near the center of the sight glass Do not overfill Foot Brake Fluid Level The brake fluid reservoir is located under the seat Q Maintain the fluid level between the maximum and minimum marks Fluid Level Mark 61 Features and Controls Parking Brake 1 Place the transmission in first gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock down to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The lock will auto matically disengage WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating 62 Features and Controls Parking Brake Important Safeguards The parking brake may relax if left on for Never depend on the parking brake alone a long period of time Always block the if the ATV is parked on a hill Always wheels to prevent rolling block the wheels to prevent rolling Always block the wheels on the downhill Place the transmission in first gear before side of the ATV if leaving it parked on a locking the parking brake hill Another option is to park the ATV in a sidehill position
88. the front 3 and rear 4 of the front rim The difference between these two measure ments should be between 0 and 1 16 0 1 5 mm toe out NOTE If you discover improper alignment see your Polaris dealer for service 163 Maintenance Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight Severe damage to the transmission and drive components can result Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain At the center point of the top side of the chain there should be 1 4 3 8 6 9 mm deflection Use the procedure on the following page if the chain needs adjustment NOTE The chain has a press on master link A chain tool must be used if it s necessary to remove the chain for service 164 Maintenance Chain Tension 1 Loosen the upper and lower pivot mounting bolts 1 2 Thread the chain adjusting bolt 2 inward or outward to adjust chain slack to the proper dimension 3 Tighten the pivot mounting bolts to 30 ft Ibs 40 Nm 4 Torque the chain adjusting bolt to 17 ft Ibs 23 Nm Proper splicelink clip opening position 165 Maintenance Handlebar Adjustment WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of co
89. the ground 4 Cover the vehicle with an appropriate cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent con densation and may promote corrosion and oxidation 184 Maintenance Transporting the ATV Ae oe Follow these procedures when transporting the vehicle Y Stop the engine Place the transmission in first gear Lock the parking brake Remove the key to prevent loss during transporting Secure the fuel cap oil cap and seat Turn the fuel valve off Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope SOY EAE US b 185 Specifications Outlaw 525 IRS Max Weight Capacity 215 Ibs 97 5 kg Pilot Jet 45 Dry Weight 395 Ibs 179 kg Main Jet 148 Fuel Capacity 3 9 gal 14 8 Needle Jet OBDVS Overall Length 71 5 in 182 cm Needle Clip 4 Overall Width 47 5 in 121 cm Slow Air Jet 100 Overall Height 45 in 114 cm Alternator Output 200 w 3000 RPM Wheelbase 51 in 130 cm Compression Ratio 11 1 Ground Clearance 11 5 in 29 cm Starting System Electric Min Turning Radius 67 in 170 cm Carburetor Keihin FCR MX 39mm Engine Oil Capacity 1 7 qts 1 6 I Ignition System CDI Coolant Capacity 2 25 qts 2 1 I Ignition Timing Supp 3 3500 RPM in neutra Engine ES51KLE Spark Plug Type NGK DCPR8E Displacement 510 cc Spark Plug Gap 0 6 mm 024 in Bore x Str
90. ting bolts 15 6M 26 100 Check torque Shift lever bolt 15 6M 26 100 Check torque E Valve clearance 15 6M 26 100 Check adjust Clutches 30 6M 52 200 Check discs for wear E Spark plug 30 6M 52 200 Replace 136 102 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used in gallons liters p General lubrication 45 3M 78 300 Lubricate all fittings pivots cables etc Carburetor float bowl 45 6M 78 300 Drain bowl periodically and prior 125 to storage WIE Throttle cable ETC switch 45 6M 78 300 Inspect adjust replace as needed 159 Drive chain s 45 6M 78 300 Inspect daily adjust lubricate if 164 needed gt H Brake pad replacement 45 6M 78 300 See your Polaris dealer Coolant strength 45 6M 78 300 Inspect strength seasonally 118 P Perform these procedures more often for vehicles subjected to severe use E Emission Related Service W Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 103 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Fuel Used in gallons liters Upper steering post 1 45 6M Inspect tighten fasteners grease after washing ATV driving in water
91. tion of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing com petition This limited warranty also does not cover physical damage corrosion or defects caused by fire explo sions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you
92. tire wear and vehicle handling which can result in serious injury or death Never install the rim with the valve stem to the inside of the vehicle Always ensure that all nuts are torqued to specification 1 2 Place the transmission in gear Lock the parking brake Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation Install the wheel bolts and finger tighten them Lower the vehicle to the ground Securely tighten the bolts to specification See page 152 153 Maintenance Boot Inspection Before Operating Inspect the boots before operating the vehicle If a boot is torn punctured or leaking fluid see your Polaris dealer for service or replacement After Operating Inspect the boots after operating the vehicle If a boot is bulging or ballooned perform the boot burping procedure on page 155 154 Bulging Boot Maintenance Boot Burping 1 Using a needle nose pliers or boot clamp removal tool remove the small boot clamp 1 from the inboard boot NOTE Do not use any tools that may damage the boot 2 Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape 2 1 3 Wipe excess grease from the shaft before returning the boot to the boot groove Use caution not to allow excess air back into the system when reinstalling the b
93. ts Indicator Lights An illuminated light in the indicator window will alert you to the follow ing conditions Hot engine Reverse gear is selected Neutral gear is selected NOTE If indicator lights fail to oper ate check connections See your Polaris dealer for inspec tion of the capacitor and volt age regulator 52 Hot Engine ORO V o L P ME x KO Reverse Neutral Features and Controls Lights Headlights WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death This vehicle is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Use the light switch to turn the lights on and off and to switch the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position X Nn Features and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar Squeeze the clutch lever toward the handlebar to disengage the clutch Disengage the clutch before shifting gears Adjusting Knob The clutch is self adjusting but lever position can be changed to fit the operator s hand Turn the adjusting knob counterclockwise to move the lever closer to th
94. uce cooling efficiency Insufficient coolant Check levels and fill as needed check for leaks Insufficient air flow due to slow operation Operate at a faster speed to increase air flow Cooling system has not been bled Bleed the cooling system Foam has formed in cooling system Drain and replace coolant with recommended coolant Bent cooling hose Shorten or replace hose Defective thermostat or thermoswitch See your Polaris dealer Blown fan fuse or defective fan Replace fuse and check fan for proper operation or see your Polaris dealer 200 Troubleshooting Engine Fails to Reach Full Power Possible Cause Solution Interrupted fuel supply Clean fuel system and carburetor Float leaks Replace the float Clogged dirty or wet air filter Inspect and clean or replace Faulty exhaust system Check system for damage see your Polaris dealer Valve gap is too small Adjust valve gap Faulty ignition timing See your Polaris dealer 201 Warranty LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covere
95. vided with printed materials that explain safe operating procedures You should review this information on a regular basis Safety If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area Follow the recommended maintenance program outlined in your owner s manual This program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals Safety Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety 1s involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 16
96. wer Possible Cause Solution Out of fuel Turn the fuel valve to reserve refuel Interrupted fuel supply Clean fuel system and carburetor Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer 198 Engine Stops or Loses Power Troubleshooting Possible Cause Solution Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plug Inspect clean and or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC Old or non recommended fuel Replace with recommended fuel 199 Troubleshooting Engine Overheats Possible Cause Solution Debris lodged in screen Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radia tor fins NOTE High pressure washers can deform the radiator fins and red
97. which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this war ranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery mate rial corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WAR RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 203 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DUR
98. which will allow short term operation only to drive the ATV to a trailer or towing vehicle Do not perform the following procedures if you don t feel completely capable or if you sus pect that water has entered the fuel tank likely if the water was deep or if the ATV over turned Tow or trailer the ATV to your dealer for immediate service 142 Maintenance Vehicle Immersion 1 Turn the fuel valve off 2 Drain water from the air box and clean the air filter See page 122 3 Drain the carburetor bowl See page 125 4 Remove the spark plug See page 138 A WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Stand clear of the spark plug while performing the following steps 5 Intermittently and briefly touch the starter button in half second intervals to SLOWLY rotate the engine three or four times Water will eject from the spark plug hole continued on following page 143 Maintenance Vehicle Immersion 6 Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole 7 Check the oil level If the level is higher than the pre ride inspection level water has entered the crankcase Do not start the engine Transport the vehicle to your dealer for inspection and service If the oil level is unchanged from the pre ride inspection level replace th
99. will meet the efficiency requirements of 43 CFR 8343 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 205 Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s war ranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Recalls 206 Warranty EXPORTED VEHICLES How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle
100. y Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight care fully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads 21 Safety Operator Safety Always check for obstacles or people Never modify an ATV through improper behind the ATV before operating in installation or use of accessories reverse When it s safe to proceed in Never exceed the stated load capacity for reverse move slowly and avoid turning at your ATV sharp angles i Always remove the ignition key when the vehicle is not in use to prevent unautho rized use or accidental starting Always use the size and type of tires specified for your ATV and always main tain proper tire pressure FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 22 Safety Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or pow
101. ystem Cooling System Bleeding Bleeding the cooling system is required only if the system has been drained for maintenance and or repair Always allow the engine to cool sufficiently before removing the radiator pres sure cap 1 Remove the pressure cap 2 Using a funnel slowly add the recommended coolant Fill the radiator to the bottom of the filler neck 3 Reinstall the pressure cap Start the engine and allow it to idle for five minutes or until operating temperature is reached 5 Stop the engine 6 After the engine has cooled add additional coolant to refill the radiator to the bottom of the filler neck 7 Operate the vehicle for 20 minutes allow the engine to cool then recheck the coolant level in the radiator Add coolant as needed 121 Maintenance Air Filter Systems NOTE Refer to the illustrations on page 123 Remove the seat Release the airbox cover clips and remove the cover Loosen the filter clamp Remove the air filter from the box Locate the retaining spring Carefully remove the retaining spring from the filter Remove the inner and outer foam filter elements from the internal cage Separate the two filters Wash the filters in soapy water then rinse and let dry Apply a commercially available foam filter lubricant to the foam filters Reinstall all components 10 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 9 n t 122 Maintenance Air
102. z cartridge 2871460 Starter Drive Grease 2 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz 1350046 Rear Shaft Grease 30 g 188 Polaris Products Part Number Description Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2876335 Hydraulic Clutch Oil qt 189 Troubleshooting See your Polaris dealer if you re unable to identify solutions using the following charts Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Turn the fuel valve to reserve refuel Water is present in carburetor or fuel supply Clean carburetor and or drain fuel system and refuel Fuel valve is turned off Turn the fuel valve on Engine is cold Use choke to start a cold engine Interrupted fuel supply Turn the fuel valve off remove the fuel hose at the carburetor and place in a drain pan turn the fuel valve on ffuelleaks out clean the carburetor fno fuel leaks out clean the fuel valve Clogged fuel valve or filter Inspect and clean or replace Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect and clean or replace plug s Incorrect spark plug gap

Polaris Outlaw 525 IRS User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents