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Polaris 9922079 Offroad Vehicle User Manual

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1. Equipment Modifications Etiquette Trail Riding Exhaust Exposure to Eye Protection 197 Index F Fluid Brake nie 22 oA pO RIS 48 49 Clutch hear 43 Foot Brake 0 0005 46 Foot Brake Fluid Level 49 Fuel Filter 00 56 Fuel Safety eosam ER 17 Fuel Stabilizer 165 Fuel Tank ets 56 Fuel Valve cyber xS 57 G Gasoline Handling 17 GLOVES ees phones IR IeR Eis 14 H Hand Brake 0 47 Hand Brake Fluid Level 49 Handlebar Adjustment 150 198 H Headlight Adjustment 115 Headlight Assembly 118 Headlights 41 Helmet nso secede tia ot 13 l Idle Speed 0 0 112 Indicator Lights 40 Instruction Operating 16 J Jet ng creda AERE 114 169 K Key Switch 39 K Tum oo s RR 76 L Lights 40 41 115 119 Brake Light 119 Headlight Adjustment 115 Headlight Assembly 118 Headlights 41 Indicator Lights 40 M Main Key Switch 39 Maintenance Chart 85 95 Making Turns 69 Manual Shift 52 55 Master Cylinder 48 49 Modifications 12 Oo Oil Change Engine 98 105 Oil Level Engine 97 Oil Recommendations 96 Opera
2. 146 147 Trail Etiquette i eneee Os 65 Transporting the ATV 167 Tread Lightly 64 Turning Around on a Hill 76 77 V Vehicle Identification Numbers 8 Vehicle Immersion 126 128 Ww Warranty Emissions 191 192 Washing the Vehicle 160 162 Wheel Hub Tightening 136 Wheel Installation 137 Wheel Removal 136
3. 7 Move the engine stop switch to the RUN position Turn the ignition key to ON 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 52 Do not apply throttle Press the start button to start the engine Activate the starter for a maximum of five seconds Release the start button immediately when the engine starts NOTICE Excessive engagement may result in starter damage 8 If the 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 If the engine does not start review the engine troubleshooting information beginning on page 172 If all conditions are favorable and the engine still does not start see your Polaris dealer for service Push the choke knob completely in Vary engine speed slightly with the throttle to aid in warm up 67 Operation Driving Procedure 1 Wear a helmet and eye protection 2 Sit upright with both feet on the footpegs and both hands on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear See page 52 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress
4. 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 109 Maintenance Air Filter Systems Refer to the illustrations on page 111 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 0 9 n 9 ROM 110 Maintenance Air Filter Systems 111 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 operatio
5. 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 174 Engine Backfires Troubleshooting Possible Cause Solution Weak 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 175 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 batte
6. 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 170 for the part numbers of Polaris prod ucts Hand Brake Fluid Level 1 Position the ATV on a level surface Position the handlebars so the master cylinder is level 2 View the fluid level through the indicator window on the side of the master cylinder 3 Maintain the fluid level at or slightly above C2 the mark near the center of the sight glass Do not overfill Foot Brake Fluid Level 1 Position the ATV on a level surface 2 Remove the seat and view the fluid level in the reservoir Maintain the fluid level between the maximum and minimum marks Fluid Level Mark 49 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 inward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The lock will automati cally disengage WARNING Operating the ATV while the parking brake is engaged could result in an accident Always check to be sure the parking brake is disengaged before operating 50 Features and Controls Parking Brake The parking brake may relax if left on for a long period of time Always block the w
7. The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage 6 Q The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard AWARNING Failure to follow the warnings and safety precautions contained 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 this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training
8. Hand Brake The hand brake operates the front brakes The hand brake is located on the right handlebar These brakes are hydraulically activated disc type brakes Squeeze the brake lever toward the handlebar to engage the front brakes Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs Features and Controls Hand Brake Front Brake WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever Always contact your dealer for service before operating the vehicle 47 Features and Controls Master Cylinder Brake Fluid AWARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill 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 brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion 48
9. 100 Check adjust Clutches 30 6M 52 200 Check discs for wear E Spark plug 30 6M 52 200 Replace 122 90 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page 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 113 to storage WIE Throttle cable ETC switch 45 6M 78 300 Inspect adjust replace as needed 143 Drive chain s 45 6M 78 300 Inspect daily adjust lubricate if 149 needed gt H Brake pad replacement 45 6M 78 300 See your Polaris dealer Coolant strength 45 6M 78 300 Inspect strength seasonally 106 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 91 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Fuel Used in gallons liters 9 Upper steering post 1 45 6M Inspect tighten fasteners grease after washing ATV driving in water p Front A Arms 2 45 6M Inspect tighten fasteners grease also after washing ATV or driving in water pe Stabilizer Ba
10. Clean out 124 L Front rear wheel bearings 300 36M Inspect replace as needed E Toe adjustment As required Inspect periodically adjust when 146 parts are replaced Headlight aim As required Adjust as needed 115 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 95 Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 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 Do not use Polaris PS 4 Performance Synthetic 10W 40 Oil Always use 2W 50 See page 170 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands If the 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 crank case Water in the bottom of the crankcase can lead to engine damage and must be drained Change the oil immediately if the oil level rises 96 Maintenance Engine Oil Level Sight Glass Check the oil level before each
11. width Be constantly alert for hazards such as v NO logs rocks and low hanging branches lt 3 Travel slowly and use extra caution z when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees 79 Operation Driving Through Water Polaris does not recommend operating in water deeper than the height of the footpegs Follow these procedures when operating through water 1 Determine water depth and current before entering water 2 Choose a crossing where the water level is lowest and where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water 80 VY ties p LA 54 MN E aximum Depth ES ae Operation Driving Through Water NOTICE Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footpeg level As soon as possible perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 85 Engine oil and all grease fittings need special attention If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow
12. Allow it to cool before resuming charging The battery may be recharged without removing it from the vehicle Attach cables in the fol lowing order 1 Attach the positive cable clamp to the positive battery terminal 2 Attach the negative cable clamp to the negative battery terminal 132 Maintenance Battery Charging Sealed Battery 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 pre determined point If the battery fails to recharge during vehicle operation check voltage regulator connections See your Polaris dealer for inspection of the voltage regulator and generator 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 133 Maintenance Battery Charging Sealed Battery 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 100 12 8 13 0 volts None check at 3 months from None required date of manufacture 75 100 12 5 12 8 volts May need slight charge if no 3 6 hours charge given check in 3 months 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 vo
13. Charging 132 134 Installation 131 Maintenance 129 Removal velie 130 Storage eenean ia 130 163 Bleeding the Cooling System 109 BoOOts o ieor aana ety tes 14 Brake Fluid 48 49 Brake Light Adjustment 119 Brake Maintenance 144 145 Brakes Foot Brake 2 0008 46 Hand Brake 47 Parking Brake 50 51 Break in Period 58 59 C Cab Removal Front 120 Cab Removal Rear 121 Camber and Caster 151 Carburetor 112 113 Carburetor Draining 113 Carburetor Jetting 114 Chain Tension 148 149 Chain Tension Inspection 149 Cleanings i oec 160 162 Clothing e sepe ott 14 Clutch Fluid 0 43 Clutch Lever 42 Clutch System Bleeding 140 141 Compression Damping Rear 159 Consumer Product Safety 11 Coolant Level Radiator 108 Coolant Level Recovery Bottle 107 Cooling System 106 109 Cooling System Bleeding 109 Deceleration Driving Downhill Driving in Reverse Driving on a Sidehill Driving on Slippery Surfaces Driving Over Obstacles Driving Procedure Driving Through Water Driving Uphill Electronic Throttle Control Emission Control Systems Engine Idle Speed
14. 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 power 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 ATV 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 The addition of certain accessories including but not limited to mowers blades tires sprayers 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 12 Safe 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 When ever 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 roundi
15. Number 1 Engine Serial Number 2 Key Number on the key Introduction Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV 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 10 You were also provided with printed materi als that explain safe operating procedures You should review this information on a regular basis 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 Safety Safety Training A Polaris ATV is an off road vehicle Follow the recommended maintenance Familiarize yourself with all laws and program outlined in your owner s manual regulations concerning the operation of this This program is designed to ensure that all vehicle in your area critical components on your vehicle are thoroughly inspected at specific intervals 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 Safety Equipment
16. a Polaris dealer to ensure that it s done correctly Mechanically knowledgeable persons who perform this procedure must follow the adjustment procedures exactly 1 2 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Maintenance Boot Adjuster Lock Nut 143 Maintenance Brakes Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed 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 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 ope
17. and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 161 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 If warning and safety labels are damaged contact your Polaris dealer for free replacement Avoid direct ing the water stream at the following items Wheel bearings Brakes Electrical components and wiring Cab and body panels Transmission seals Labels and decals 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 162 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 Que 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 Storage NOTICE 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 r
18. fuel supply Use choke to start a cold engine Turn the fuel valve off remove the fuel hose at the carburetor and place in a drain pan turn the fuel valve on If fuel leaks 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 Adjust gap to specification 172 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 173 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
19. 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 191 Warranty U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option 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
20. lamp clean it with denatured alcohol 1 Remove the wire harness connector from the back of the headlight 2 Grasp the bulb housing and turn it counterclockwise to remove the bulb CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 3 Apply dielectric grease to the socket and install the new bulb Rotate firmly 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 117 Maintenance Lights Headlight Assembly Replacement Remove the front cover Remove the wire harness connector from the headlights Remove the two retaining brackets and the adjuster screw Remove the headlamp Install the new headlamp placing it in the slots on the frame tabs Secure the headlamp with the retaining brackets Install the adjuster screw leaving it loose so the headlight can be adjusted be or L Connect the wire harness to the headlamp Reinstall the front cover 8 Adjust the lamp as needed see page 115 then tighten the adjuster screw 118 Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle Body 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 Spring 3 Ifthe light do
21. lever As engine speed RPM increases in first gear simultaneously release the throttle disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke Repeat this proce dure to progressively upshift to addi tional gears 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 53 Features and Controls Manual Shift Reverse Lock Out Switch The reverse lock out switch prevents the operator from shifting into reverse uninten tionally The switch must be manually unlocked before shifting into reverse gear The lock will automatically re engage when the transmission is shifted out of reverse gear 1 Place the transmission in first gear See page 52 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into reverse gear 54 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 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 speed is too high can cause the tires to lose traction or s
22. of the ATV turn the handlebars full left 6 Reach across the handlebar and apply the front brakes to unlock the parking brake 76 Turning Around on a Hill 7 11 Release the parking brake and slowly release Operation 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 the clutch lever allowing the ATV to proceed slowly Stay in first gear using the brakes for additional speed control if necessary until more level ground is reached Follow proper procedures for driving downhill See page 75 77 Operation 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 78 Operation Driving Over Obstacles Follow these precautions when operating over obstacles m cues e em gt 1 Always check for obstacles before oper E ating in a new area E 2 Look ahead and learn to read the terrain
23. result in severe injury or 7175378 death Cold tire pressure Tire Pressure Front 4 0 psi 27 6 kPa PNE Warning Rear 4 0 psi 27 6 kPa Maximum Weight Capacity 215 Ibs 98 kg 7175445 37 Features and Controls Engine Stop Switch Start Button 38 Main Key Switch Features and Controls Main Key Switch The main key switch must be in the RUN position to start the engine See page 66 for starting procedures Start Button Press the start button to engage the starter Always release the start button promptly when the engine starts If the 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 B not start or run when the switch is off ES Both the main switch and the engine stop switch will OFF RUN OFF shut off all electrical power to the vehicle including lights 39 Features and Controls Lights Hot Engine Reverse Neutral 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 If indicator lights fail to operate check connections See your Polaris dealer for inspection of the capacitor and voltage regulator 40 Features and Controls Lights Headlights Use the headlight switch to turn the lights on an
24. the EMC requirements of European directives 97 24 EC and 2004 108 EC 84 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 maintenance procedures outlined in the Periodic Main tenance Chart will result in forfeited warranty coverage as well as decreased performance and reliability of the vehicle f you re unable to perform the required service and adjustment procedures have a qualified dealer perform these operations 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 193 85 Maintenance Periodic Maintenance Chart The recommended service intervals are based on average riding conditions Vehicles sub jected 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 86 Maintenance Periodic Maintenance Chart AWARNING Improperly performing the procedur
25. use extreme caution and always follow proper operating procedures as outlined in this manual See page 79 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding 29 Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating through deep or fast flowing water If it s unavoidable to enter water that exceeds the height of the footpegs Travel slowly Balance your weight carefully Avoid sudden movements 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 After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads 30 Safety Safety Warnings Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out he
26. 1 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 1 Ignition System CDI Coolant Capacity 2 25 qts 2 1 Ignition Timing 25 3 3500 RPM in neutral Engine ES51KLE Spark Plug Type NGK DCPR8E Displacement 510 cc Spark Plug Gap 0 6 mm 024 in Bore x Stroke 95 x 72 mm Lubrication System Dry Sump Internal Reservoir 168 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 10R10 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 Dual Beam 55w 60w Gear Ratio 5th 1 130 Taillights LED Gear Ratio Reverse 2 429 Brakelight LED Jetting Chart ALTITUDE AMBIENT TEMPERATURE Meters Feet Below 40 F Below 5 C 40 F and above 5 C and above 0 1800 0 6000 Main Jet 158 Main Jet 148 Needle Clip Position 4 Needle Clip Position 44 1800 3700 6000 12000 Main Jet 148 Needle Clip P
27. 2009 POLARIS Outlaw 525 IRS Owner s Manual for Maintenance and Safety ic E 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 vears of age Read this manual carefully It contains important safety information AWARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY AN APPROVED ON PUBLIC PASSENGERS HELMET AND ROADS PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS NEVER USE WITH DRUGS OR ALCOHOL POLARIS The Way Out NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control 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 9922079 Rev 01 Printed in USA AWARNING The engine exhaust from this product contains ch
28. 60 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 139 Oil and filter change Change the oil and filters 98 Oil screen drain plug 3 Break in 5 20 Clean screen and plug magnet 100 Idle speed Check idle speed setting 112 Engine mounting bolts Check torque Valve clearance Check adjust enmy m 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 89 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 145 Rear sprocket bolts 10 Monthly Check torque 149 Battery 10 Monthly Check terminals clean test 129 PE Air filter 15 Weekly Inspect clean replace as needed 110 gt Oil and filter change 15 6M 26 100 Perform initial oil change after first 98 3 hours of operation gt Oil screen drain plug 15 6M 26 100 Clean screen and plug magnet 100 Idle speed 15 6M 26 100 Check adjust as needed 112 Engine mounting bolts 15 6M 26 100 Check torque Shift lever bolt 15 6M 26 100 Check torque E Valve clearance 15 6M 26
29. E 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 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 OTHE
30. FR 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 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr 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 All exhaust gases exit through the exhaust system 83 Emission Control Systems 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 perform 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 Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with
31. R 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 185 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 DURATION 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 186 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 right
32. UTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 5 6 Position the vehicle on a level surface Remove the skid plate for better access to the oil drain plug and short screen Start the engine Allow it to idle for two to three minutes Stop the engine Place a drain pan beneath the crankcase Remove the drain plug Allow the oil to drain completely Clean the crankcase sealing surface and the Drain Plug drain plug with magnet thoroughly Replace the sealing ring Reinstall the drain plug Torque to 15 ft Ibs 20 Nm 99 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Oil Screen Plug Short Screen View from bottom of vehicle 100 Maintenance Engine Oil Change Cleaning the Short Oil Screen 1 2 3 Remove the short oil screen 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 101 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 thoroughly and blow with compressed air 3 Check
33. adlamps promptly Improper Cargo Loading Overloading the ATV or carrying towing cargo may cause changes in handling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes or steering The object may overturn or collide with other objects Never exceed the stated load capacity for this ATV 31 Safety Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems 32 Physical Skills 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 Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caut
34. amber and caster are non adjustable 151 Maintenance Front Suspension Suspension Set Up 1 2 3 152 Position the vehicle on a level surface Stop the engine Elevate the front of the vehicle by placing a suitable stand under the frame The tires should be barely touching the ground and the suspension should be at full rebound Measure the distance from the ground to the bottom of the lower front bumper bolt Note this measurement for later use Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars Maintenance Front Suspension Suspension Set Up 6 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 7 Turn the handlebars fully to the left and right 8 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 9 Ifthe number is less than 3 75 inches 9 5 cm decrease the front spring preload see page 154 and repeat all steps If the number is higher than 4 inches 10 2 cm increase spring preload and repeat all steps 153 Maintenance Front Suspension Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor
35. ating on Slippery Terrain 27 Operating on Steep Hills 23 Operating Over Obstacles 29 Operating Through Deep Water 30 Operating Without Instruction 16 Physical Control of the ATV 21 Physical Skills 32 Poor Visibility 31 Protective Apparel 18 Skidding or Sliding 29 Stalling While Climbing a Hill 26 Turning Improperly 22 Unauthorized Use of the ATV 33 Unfamiliar Terrain 28 Using Alcohol or Drugs 19 Safety Words and Symbols 6 Service Requirements 8 Severe Use vesc ET 86 Shift Pedal oo one bbe boa sie 52 Shifting Gears 53 199 Index S Side Panel Removal Sidehilling Signal words Spark Arrestor Clean Out Spark Plugs Spring Preload Spring Preload Front Spring Preload Rear Starting the Engine Steering Inspection Storage us over E ess Suspension PRONG och Ae Seed 200 152 155 156 159 152 157 S Switches Engine Stop Switch 39 Main Key Switch 39 Reverse Lock Out Switch 54 Start Button suus 39 T Throttle Cable Freeplay 143 Throttle Lever 44 45 Throttle Lever Freeplay 142 Tires 4 e n m pm 135 Installation 137 Removal 136 Tread Depth 135 Wheel Hub Tightening 136 Toe Alignment
36. ause 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 179 Troubleshooting Engine Stops or Loses Power 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 180 Troubleshooting Engine Stops or Loses Power 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 s
37. ause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill 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 Ifthe vehicle begins to slide or tip quickly turn the front wheel down hill if possible or dismount on the uphill side immediately 74 Operation Driving Downhill Whenever descending a hill follow these precautions 1 Avoid steep hills 25 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when trav eling downhill can cause loss of control 5 Shift to the lowest gear possible while maintaining a safe speed 6 Do not apply the brakes abruptly when driving downhill Apply the foot brake slightly to aid in slowing 75 Operation Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Keep your body weight uphill 2 Pull in 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
38. course Purchasers of a new Polaris ATV and their eligible 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 RiderCourses Introduction This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 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 Introduction Service Requirements 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 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
39. d off and to switch the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights Headlight Switch 41 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 the handle bar Turn the adjusting knob clockwise to move the lever away from the handlebar 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 43 If the lever begins to feel unresponsive bleed the clutch system as outlined on page 140 42 Clutch Fluid The clutch fluid master cylinder is located on the left handlebar Check the fluid level in the reservoir 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 170 for the part numbers of Polaris product
40. e first three hours of use Vary throttle positions Do not operate at sustained idle Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 60 At the end of the break in period 3 hours change the engine oil and the long and short oil filters See page 98 Clean the oil screen and drain plug magnet 59 Operation Pre Ride Inspection Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Pre Ride Checklist Page Brake systems lever travel Ensure proper operation 46 51 144 145 Brake fluid Ensure proper level 48 Clutch lever Check for proper operation and adjustment 42 Clutch fluid Ensure proper level 43 Suspension front and rear Inspect lubricate if necessary 92 Steering Check for free operation loose components Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 56 97 60 Pre Ride Inspection Operation Pre Ride Checklist Page Coolant if applicable Ensure proper level 107 Coolant hoses if applicable Inspect for leaks Throttle Ensure smooth operation 44 Indicator lights switches Ensure operation 40 41 Engine stop switch Ensure proper operation 39 Air filte
41. e oil see page 96 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 97 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 Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 170 for the part numbers of Polaris products 106 Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender If the fluid level is vis ible at the bottom of the side panel add 6 oz 175 ml of coolant As coolant operating temperature increa
42. each time throttle is applied Do not squeeze the throt tle lever while starting the engine Do not squeeze the throttle lever when the engine is stopped Engine speed returns to idle when the lever is released See page 143 for throttle adjustment procedures This ATV is equipped with an Electronic Throttle Con trol ETC which is designed to reduce the risk of a fro zen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop Throttle Lever 45 Features and Controls Foot Brake The foot brake operates the rear brakes The brake pedal is located 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 119 WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill 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 Foot Brake Rear Brake Footp6g 46
43. ecommended See page 160 Battery Storage Refer to pages 129 134 for battery storage and battery charging procedures 163 Maintenance Storage Engine Oil Change the oil and both filters Clean the oil screens See page 98 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 85 Transmission Oil Engine Oil e Coolant test strength fill Brake Fluid Clutch Fluid 164 Maintenance Storage Stabilize the Fuel 1 2 n0 h Fill the fuel tank with fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount 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 promotes better starting after the storage period 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 113 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 ti
44. emicals 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 2008 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 2009 Outlaw 525 IRS ATV Owner s Manual P N 9922079 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 All terrain vehicles ATVs RANGER utility vehicles Victory motorcycles We
45. en 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 25 and 4 5 inches 10 8 11 4 cm If the number is less than 4 25 inches 10 8 cm decrease the rear spring preload on both shocks see page 158 and repeat all steps If the number is higher than 4 5 inches 11 4 cm increase spring preload and repeat all steps 157 Maintenance Rear Suspension The rear suspension spring preload and shock compression Q ET Don bem uiuos 0 e Adjusting damping may be adjusted to suit different riding conditions Jared Ring and operator weight upper lower Spring Preload 1 Raise and safely support the rear of the vehicle off the ground to allow the suspension to fully extend h J Loosen the jam nut Increase Decrease 3 Turn the adjusting ring clockwise to increase preload Preload Preload Turn the ring counter clockwise to decrease preload 4 Tighten the jam nut firmly against the adjusting ring 5 Measure the preload of the left and right shocks Make sure both shock measurements are equal 158 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 s
46. es marked with a lil could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt 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 87 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 60 88 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page in gallons liters Air box sediment tubes Pre ride Check each day before operating
47. es 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 TIP 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 119 Maintenance Front Cab Side Panel Removal The front cab and side panel assembly is removed in one piece 1 Remove the seat 2 Remove the two front cover screws and remove the front cover 3 Remove the eight side panel screws four on each side 4 Remove the fuel cap 5 Gently pull the side panel cab assembly upward and rearward 6 Unplug the key switch and the indicator panel before removing the cab 7 To remove a side panel from the cab remove the corre sponding push pin and slide the panel forward to disen gage the locking tabs Side Panel Screws 120 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 and grommets 2 on the top of the cab Remove the two bolts 3 at the rear cab to front cab joint Unplug the taillight connector Remove the cab 121 Maintenance Spark Plugs Refer to the specifications section beginning on page 168 for recom
48. es overly rich An engine loses approximately 3 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 Contact your dealer for altitude adjustments Your dealer has the training and special tools required to perform these modifications 114 Maintenance Lights Headlight Adjustment 1 2 3 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Start the engine and turn the headlight switch to high beam 25 ft 7 6 m gt Lamp Center Height 2 5cm 1 General Representation 115 Maintenance Lights 4 5 6 116 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 Include rider weight on the seat when measuring Loosen the pivot screw and adjust the beam to the desired position Tighten the screw and torque to 27 in Ibs 3 Nm Pivot Screw Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp avoid touching the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp If fingers do touch a
49. et the shock at the firmest setting turn the screw clockwise until it stops fully closed position From this position turn the screw counter clockwise to decrease compression damping Setting Compression Damping Softest 24 clicks from closed Factory 8 clicks from closed Firmest 2 clicks from closed Maintenance Compression Adjustment 159 Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE 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 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 160 Maintenance Cleaning Washing the Vehicle 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
50. ety Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special tech nique is required when braking while traveling downhill See page 75 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Shift your weight rearward 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 24 Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 74 Never attempt 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 76 Grn S AX Web NI S 25 Safety Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a h
51. f road enthusiast you repre sent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails 64 Operation Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 65 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 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 NOTICE Operating the ATV immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 1 Shift the transmission to neutral Choke Knob 2 Lock the parking brake Turn the fuel valve on _ 3 Sit on the vehicle Disengage the rn VE clutch H 4 Ifthe engine is cold pull the choke knob out until it stops Do not use the choke if starting a warm engine 66 Operation Starting the Engine 5 6
52. 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 and recharge as needed to maintain a full charge Battery Removal 1 Disconnect the hold down strap securing the battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Lift the battery out of the ATV 130 Maintenance Battery Installation 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 1 Place the battery in the battery holder 2 Connect and tighten the red positive cable first 3 Connect and tighten the black negative cable last 4 Attach the hold down strap 5 Verify that cables are properly routed 131 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 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
53. from the footpegs during operation can reduce Always operate at a speed that s appropriate for your ability to control the vehicle or cause loss of the terrain the visibility and operating conditions balance and ejection from the ATV If the and your experience operator s foot is not firmly planted on the footpeg it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footpegs 21 Safety Safety Warnings Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds 22 Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Safety Safety Warnings Improper Hill Climbing Operating on Steep Hills Improper hill climbing could cause loss of control Operating on excessively steep hills could cause or overturn Always follow proper procedures for an overturn Never operate on hills too steep for climbing hills as described in the owner s the ATV or for your abilities Never operate the manual See page 72 ATV on hills steeper than 25 degrees 23 Saf
54. gnition timing See your Polaris dealer 183 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 covered 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 184 Warranty WARRANTY COVERAG
55. 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 154 Front Suspension Spring Preload 1 Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend Loosen the jam nut Turn the adjusting ring clockwise to increase preload Turn the ring counter clockwise to decrease preload Tighten the jam nut firmly against the adjusting ring Measure the preload of the left and right shocks Make sure both shock measurements are equal Maintenance Jam Nut upper Increase Preload Adjusting Ring lower Decrease Preload 155 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 placing a suitable stand under the frame 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 156 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 t
56. he racks if equipped and the load on the trailer tongue if equipped The combined weight of these items must not exceed the maximum weight capacity Safe Operation Practices 8 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the han dlebars while operating and always keep both feet on the footpegs Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Operation Never operate a damaged ATV After any overturn or accident have a quali fied service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust system com ponents Always keep combustible materials away from the exhaust sys tem Always remove the ignition key when the vehicle is not in use to prevent unau thorized use 63 Operation Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off road vehicle in your area Respect the environment in which you ride Find out where the desig nated riding areas are by contacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an of
57. heads If not tighten the bolts to 28 ft Ibs 38 Nm 6 Bend the retaining tabs tightly against the flat edges of the bolt heads If a tab cannot be aligned with a flat edge it should be bent around a point of the bolt head TIP If a retainer tab does not align with the flat edge of a bolt head the bolt can be tightened to a maximum of 38 ft Ibs 51 Nm Maintenance Proper splicelink clip opening position 149 Maintenance Handlebar Adjustment A 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 control 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 Ibs 14 16 Nm then torque the two rear bolts A gap of up to 1 8 3 mm will remain at the rear bolts 150 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 in the steering post see your Polaris dealer for service before operating the vehicle Camber and Caster The c
58. heel 136 Maintenance Wheel Installation 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 136 137 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 139 138 Bulging Boot Boot Burping 1 Using a needle nose pliers or boot clamp removal tool remove the small boot clamp 1 from the inboard boot Do not use any tools that may damage the boot 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 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 boot Reinstall the boot clamp Maintenance 139 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out lined in the Periodic Maintenance Cha
59. heels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Place the transmission in first gear before locking the parking brake 51 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 53 To shift into reverse see page 54 on on Downshift 52 Manual Shift Shifting Gears Always allow a cold engine to warm up before shifting gears 1 2 3 4 When starting from a stopped position place the transmission in neutral Squeeze and hold the brake lever Do not apply throttle Squeeze the clutch lever to disengage the clutch Depress the gear shift pedal one full stroke to shift into first gear Features and Controls Release the brake lever Gradually squeeze the throttle lever while slowly releasing the clutch
60. icle 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 warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 190 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
61. ilated area Do not smoke or allow open flames or sparks in or near the area where refueling is per formed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 17 Safety Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 18 Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident Always wear an approved helmet that fits properly Always wear eye protection goggles or face
62. ill If all forward speed is lost Keep body 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 downhill Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 76 26 Safety Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn 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 27 Safety Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain c
63. ing 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 E 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 94 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 change yearly 140 HE Jet needle needle jet 180 24M Replace E Brake fluid 180 24 M Replace Spark arrestor 300 36 M
64. ion when traveling through tall grass especially dry grass Safety Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 33 Safety Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part num ber is printed on the label 34 Discretionary Sport ATV Warning General Warning Age 16 Warning Safety Labels and Locations 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 at speeds too fast for your skills or the condi tions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing contr
65. lcome 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 4 return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Pure Polaris products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door IntrodHetiortis oso RE ER ERE 6 SAC ine ote wits t en Lu wis 10 Features and Controls 38 Operation sk aes esa ees 58 Emission Control Systems 86 Maintenance 85 Table of Contents Specifications 168 Polaris Products 170 Troubleshooting 172 Warranty us deeds d pepe 184 Maintenance Log 193 EMG PPP NTC EMPTUM UMS 197 Introduction Safety Words and Symbols
66. lts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating At least 20 hours charger 134 Maintenance Tires AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Always ensure that all nuts are torqued to specification Tire Tread Depth i Always replace tires when tread depth is 1 8 8 mm worn to 1 8 3 mm or less d NS 135 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 All 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 w
67. mended spark plug type and gap NOTICE Using non recommended spark plugs can result in serious engine damage 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 Spark has been warmed up and the vehicle has been driven at higher Plug speeds Immediately check the spark plug for correct color 1 Access the spark plug at the right side of the engine 2 Using the spark plug socket and a wrench rotate counter clockwise to remove the spark plug CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 3 After reinstalling the spark plug torque to 14 ft Ibs 19 Nm 122 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 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
68. mes to distribute the oil onto the cylinder walls Reinstall the spark plug Torque to specification 165 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 85 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 the ground 4 Cover the vehicle with an appropriate cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 166 Maintenance Transporting the ATV Follow these procedures when transporting the vehicle CIE er Stop the engine PX TE y PON A 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 r3 167 Specifications Outlaw 525 IRS Max Weight Capacity 215 Ibs 97 5 kg Pilot Jet 45 Dry Weight 389 Ibs 176 kg Main Jet 148 Fuel Capacity 3 1 gal 11 7 Needle Jet OBDVS Overall Length 71 5 in 182 cm Needle Clip 4 Overall Width 47 5 in 12
69. n 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 5 Ifidle speed is unsatisfactory after performing this procedure see your Polaris dealer for information about jetting changes 112 Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 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 113 Maintenance Carburetor Jetting Carburetor re jetting can be performed to compensate for altitude and or temperature changes If the vehicle is 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 becom
70. ng the letter E followed by the distinguishing num ber of the country which has granted approval The approval number and serial number will also be displayed on the label Long Sleeves Eye Gloves Long Pants Boots 051039 0006 31 Safety Safe 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 sleeves and long pants to protect arms and legs Riding pants with knee pads and a jersey with shoulder pads provide the best protection 14 Safety Safety Warnings AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operator Restrictions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years
71. 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 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 Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain 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 RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org 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 16 Safety Warnings Handling Gasoline 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 vent
72. of the tires even with the hub axle center line Measure the distance between the marks and record the measurement 2 Subtract measurement 2 from measure ment 1 The difference is the vehicle toe alignment The recommended toe alignment is 0 to 1 16 0 1 6 mm toe out This means that the front measurement should be 0 to 1 16 0 1 5 mm greater than the rear mea surement If you discover improper alignment see your Polaris dealer for service 147 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 following procedure if the chain needs adjust ment TIP The chain has a press on master link A chain tool must be used if it s necessary to remove the chain for service 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 148 Chain Tension 3 Tighten the pivot mounting bolts to 30 ft lbs 40 Nm 4 Torque the chain adjusting bolt to 17 ft Ibs 23 Nm 5 Check sprocket bolts to make sure the retainer tabs fit tightly against the bolt
73. ol Safety ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seri ously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 35 Safety Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 36 Discretionary Sport ATV Warning WARNING Neveroperate this ATV on HILLS steeper than 25 degrees 25 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns This ATV may exceed the performance of other ATVs you may have ridden in the past This 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 7175637 Safety Safety Labels and Locations No Passenger Warning Tire Pressure Load Warning WARNING WARNING NEVER ride as a passenger Improper tire pressure or overloading can cause Passengers can cause a loss of control resulting loss of control in SEVERE INJURY or DEATH Loss of control can
74. onditions 28 Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 82 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels Safety Warnings Improper Vehicle Modifications Improper installation of accessories or modification of the ATV may cause changes in handling which could cause loss of control or an accident 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 See your authorized Polaris ATV dealer for more information Safety Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable
75. or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period 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 No single action on your part is as impor tant as following the procedures for a proper break in Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both 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 engine speed below 75 of capacity NOTICE Failure to perform the recommended break in maintenance can result in serious engine damage 58 Break In Period Perform the following break in and maintenance procedures carefully 1 Fill the fuel tank with gasoline Always exercise extreme caution whenever han dling gasoline Check the oil level Add the recom mended oil as needed to maintain the oil level in the proper range See page 97 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 Operation 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 dur ing th
76. osition 3 Needle Clip Position 43 Main Jet 138 169 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 All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz 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 170 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 171 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 Interrupted
77. pecs 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 181 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 reduce 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 182 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 i
78. r 3 45 6M Grease p Rear Control Arm Needle 90 12M Disassemble clean inspect bearings Bearings 4 seals grease reassemble 92 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first See Hours Calendar Fuel Used Page 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 gt Cooling system hoses 90 12M 156 600 Inspect Radiator 90 12M 156 600 Inspect clean external surface change coolant every 2 years HE 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 93 Maintenance Periodic Maintenance Chart Item Maintenance Interval whichever comes first Remarks Hours Calendar Fuel Used in gallons liters E Compression r
79. r Inspect clean replace as needed 110 Air box sediment tubes Drain deposits when visible Headlamp Check operation apply Polaris dielectric grease to 117 the socket when the lamp is replaced Brake light tail lamp Check operation adjust brake light switch 119 Riding gear Wear helmet goggles protective clothing 13 A arm ball joints Check freeplay If the tire moves excessively do not operate See your Polaris dealer Rear shaft assembly Check boots for tears punctures and grease leaks 138 6l Operation Safe Operation Practices 1 62 Complete the recommended safety training before operating this vehicle See page 10 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical dis abilities to operate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean head lights frequently and replace burned out headlamps promptly Never exceed the maximum weight capacity of the vehicle When determin ing the weight you are adding to the vehicle include the weight of the opera tor accessories loads on t
80. ration 144 Maintenance Brakes 1 Qv Un Pe 2 Always maintain brake fluid at the recommended level See pages 48 49 Check the brake system for fluid leaks Check the brakes for excessive travel 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 Pads should be changed when worn to 3 64 1 mm 3 64 1 mm 145 Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle The vehicle is designed for a neutral toe setting 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 1 Position the vehicle on a level surface Ensure the vehicle is at the proper ride height by placing a rider on the vehicle 2 Place the handlebars in a straight ahead position Secure the handlebars in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the hub axle center line as possible Make sure both marks are the same distance from the floor 146 Maintenance Toe Alignment 4 Measure the distance between the marks and record the measurement 1 Move the vehicle until the chalk marks are at the rear
81. ration Driving on Slippery Surfaces 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward i Turn in S cre of ski O O C C AX prow CO Co ME RID S SO l CSG D Sod x CISC 71 Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn Whenever traveling uphill follow these precautions 1 2 3 72 Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slip pery or loose surfaces Operation Driving Uphill 5 Keep both feet on the footpegs 6 Shift body weight uphill 7 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never back down a hill WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover 9 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 10 Remain alert and be prepared to take emergency action This may include quick dis mounting of the vehicle 73 Operation Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could c
82. rt beginning on page 85 Always bleed the clutch system any time the clutch lever feels unresponsive Always use the recommended fluid when bleeding the clutch system See page 43 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 140 Maintenance Clutch System Bleeding 4 Remove the bleeder screw 2 from the slave cylinder 5 Press fluid into the system until the fluid runs out of the hole 3 in the master cylinder without producing bubbles TIP Extract fluid from the master cylinder during the process to prevent overflowing 6 When finished remove the bleeder syringe 7 Reinstall the bleeder screw 8 Addor remove fluid as needed to maintain the level 4mm below the top edge of the mas ter cylinder reservoir 9 Reinstall the cover boot and screws securely 141 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 143 ne 1 8 1 5 3 mm 142 Throttle Cable Freeplay Adjustment 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
83. ry 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 176 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 Disassemble carburetor and clean the jets Other mechanical failure See your Polaris dealer 177 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 178 Engine Fails to Reach High RPM Troubleshooting Possible C
84. s 1 2 3 Position the vehicle on a level surface Turn the handlebar until the master cylinder is in a horizontal position Remove the two cover screws the cover and the rubber boot Add the recommended fluid as needed Reinstall the cover boot and screws securely Features and Controls Screws Cover Boot 43 Features and Controls Throttle Lever AWARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle 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 Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is properly installed to the throttle control 44 Features and Controls Throttle Lever The throttle lever is located on the right handlebar Squeeze the lever toward the handlebar to increase engine speed and vehicle movement Fuel is injected into the intake passage
85. s 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 oil 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 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 187 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 188 Warranty EXPORTED VEHICLES How
86. ses 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 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 add ing coolant to the recovery bottle Maintenance 107 Maintenance Engine Cooling System Radiator Coolant Level Pressure Cap 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 CAUTION Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the pressure cap 2 Using a funnel slowly add coolant as necessary through the radiator filler neck 3 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 108 Maintenance Engine Cooling System 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
87. shield gloves boots a long sleeved shirt or jacket and long pants Safety Safety Warnings Carrying a Passenger Using Alcohol or Drugs Carrying a passenger greatly reduces the Operating the ATV after consuming alcohol or operator s ability to balance and control the ATV drugs could adversely affect operator judgment which may result in an accident or overturn reaction time balance and perception Never Never carry a passenger on this ATV consume alcohol or drugs before or while operating an ATV 19 Safety Safety Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops 20 Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Safety Safety Warnings Operating at Excessive Speeds Physical Control of the ATV Operating the ATV at excessive speeds Removing a hand from the handlebars or feet increases the operator s risk of losing control
88. starting WILL result in serious engine damage Trans port the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined below This proce dure 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 126 Maintenance Vehicle Immersion 1 Turn the fuel valve off 2 Drain water from the air box and clean the air filter See page 110 3 Drain the carburetor bowl See page 113 4 Remove the spark plug See page 122 WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Wear protective eyewear and 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 Fluid will eject from the spark plug hole continued on following page 127 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
89. 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 the spark plug start the engine and move the ATV promptly to a trailer or towing vehicle NOTICE 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 128 Maintenance Battery A 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 The sealed battery is 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 129 Maintenance Battery Storage Whenever the vehicle is not used
90. 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 102 Maintenance Engine Oil Change Cleaning the Long Oil Screen 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 NOTICE 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 6 Reinstall the plug Torque to 11 ft Ibs 15 Nm 103 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 Using circle 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 Fill each 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 104 Maintenance Engine Oil Change Changing Oil Filters 6 7 8 10 11 Grease the filter cover O rings 3 Reinstall the covers and the screws Tighten screws to 4 5 ft lbs 6 Nm Remove the oil fill plug 4 Add 1 7 qts 1 6 1 of the recommended engin
91. the choke or incor rect carburetion adjustments 123 Maintenance Spark Arrestor Clean Out A WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Never go under the vehicle while it s inclined 124 Spark Arrestor Clean Out To remove accumulated carbon clean the spark arrestor at the intervals recommended in the Peri odic Maintenance Chart beginning on page 85 1 Remove the retaining screw and remove the screen from the end of the muffler 2 Use anon synthetic brush to clean the arres tor screen A synthetic brush may melt if components are warm 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 screen Torque the screw to 5 7 ft Ibs 7 9 Nm Maintenance Reducer Screen Muffler Retaining Screw 125 Maintenance Vehicle Immersion If the vehicle tips or overturns in water deeper than the footpeg level or if the engine stops during or after operating in water re
92. the throttle with your right thumb while slowly releasing the clutch lever to begin driving 8 Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces 68 Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times The wheel on the outside of the turn travels a greater distance than the inside wheel when turning and the inside tire slips traction slightly 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 turn ing in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 69 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 70 Ope
93. the vehicle immersion inspection and drying procedures outlined on page 126 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads If its unavoidable to enter water deeper than the footpeg level Proceed slowly Avoid rocks and obstacles Balance your weight carefully Avoid sudden movements Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 81 Operation Driving in Reverse Follow these precautions when operating in x reverse e 1 au TO for obstacles or people behind Le j a a 2 Always avoid backing downhill t 3 Back slowly Ahy CRON 4 Apply the brakes lightly for stopping p iS 5 Avoid turning at sharp angles ad DA ys 6 Never open the throttle suddenly while back P or TA Ve S he ing Do not operate at full throttle Use just b pL EN ji enough throttle to maintain a desired speed 7 Always look left right and behind the ATV before backing NOTICE 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 82 Emission Control Systems Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 C
94. 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 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 189 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 veh
95. top rotating which could result in loss of control NOTICE Shifting when engine speed is too high can also cause engine and drive train damage 55 Features and Controls Choke The choke assists in starting a cold engine The choke knob is located on the left side of the carburetor Refer to the engine starting procedure on page 66 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 Filters The fuel pick ups have internal fuel filters Do not attempt to clean the fuel filters See your Polaris dealer for service if you suspect the fuel filters are plugged 56 Choke Knob Features and Controls Fuel Valve The fuel valve is located on the right side of the ATV It has three positions OFF For vehicle storage and when transporting Turn the fuel valve off whenever the vehicle is stored or parked ON For normal operation RES For reserve supply if main supply is exhausted 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 Fuel Valve 57 Operation AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury
96. tor Restrictions 15 P Parking Brake 50 51 Parking on a Hill or Incline 78 Passenger Warning 37 Periodic Maintenance Chart 85 95 Polaris Products 170 Polishing 163 Pre Ride Inspection 60 61 R Restrictions Age 15 Reverse Lock Out Switch 54 Riding Area 64 Riding Gear uuu 13 14 S Safe Operation Practices 62 63 Safety Decals Age 16 Warning 36 Discretionary Warning 36 General Warning 35 No Passenger Warning 37 Sport ATV Warning 36 Tire Pressure Load Warning 37 S Safety Labels and Locations 34 37 Safety Training 10 11 Safety Warnings 15 33 Age Restrictions 15 Carrying a Passenger 19 Crossing Hillsides 25 Descending Hills Improperly 24 Exposure to Exhaust 17 Failure to Inspect 18 Handling Gasoline 17 Hot Exhaust Systems 33 Improper Cargo Loading 31 Improper Hill Climbing 23 Improper Reverse Operation 28 Improper Tire Maintenance 28 Improper Modifications 29 Jumps and Stunts 22 Operating a Damaged ATV 32 Operating at Excessive Speed 21 Operating on Frozen Water 32 Operating on Pavement 20 Safety Warnings 15 33 Index S Operating on Public Roads 20 Oper
97. use of the vehicle If the 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 97 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85 Change the oil more frequently on vehicles subjected to severe use IMPORTANT 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 Before beginning the oil change procedure read through the entire procedure Be prepared to complete the procedure entirely Do not allow the vehicle to be without oil and filter over night Always replace the oil and filters within a few hours of draining the oil NOTICE 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 98 Maintenance Engine Oil Change 1 2 3 4 CA
98. 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 should contact the Polaris War ranty Department at 1 888 704 5290 192 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 45 193 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL HOURS 60 90 194 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 195 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL HOURS 196 A Age Restrictions 15 Air Filter Systems 110 111 B Battery

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