Polaris Outlaw 525 IRS- Manuals

5 Table of Contents Know Your Vehicle . . . . . . . . . . . . 6Safety Decals . . . . . . . . . . . . . . . . 8Safety . . . . . . . . . . . . . . . . . . . . . 12Features and Controls . . . . . . . . 50Break-In Period . . . . . . . . . . . . . . 70Pre-Ride Inspection . . . . . . . . . . 72Operation ....

6 Know Your Vehicle 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 proced...

8 Safety Decals Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.If any ...

9 Safety Decals General Warning WARNINGImproper 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 fa...

10 Safety Decals Age 16 Warning WARNINGOperating 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. 7172559 Sport ATV Warning WARNINGThis ATV may exceed the performance of other ATVs you may have ridden in the past...

11 Safety Decals No Passenger Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7172566 Tire Pressure/Load Warning WARNINGIMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH.TIRE PRES...

12 Safety Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exc...

13 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings su...

14 Safety Operator Safety Operator Restrictions/Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. This category S (Sport) ATV is a high performance vehicle intended for off road use only, for sport-type recreation and for competitive us...

15 Safety Operator 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 sm available to you and your eligible family members. This training is included in the purchase price of your ATV...

16 Safety Operator Safety 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. The safety alert symbol , on your vehicle or in this manua...

17 Safety Operator Safety • Read this manual and all labels carefully. Follow all operating procedures. • Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and age eli- gible family members are entitled to take the ATV RiderCourse sm . Contact...

23 Safety Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifica...

24 Safety Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDB...

26 Safety Operator Safety WARNING POTENTIAL HAZARDFailure to follow the age recommendations for this ATV.WHAT CAN HAPPENSevere injury and/or death could occur if a child under the minimum age recommendation operates this ATV.Even though a child may be within the recommended age group for operating s...

27 Safety Operator Safety WARNING POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.HOW TO AVOID THE HAZARDNever carry a p...

28 Safety Operator Safety WARNING POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of c...

29 Safety Operator Safety WARNING POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's...

30 Safety Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.Operating without...

31 Safety Operator Safety WARNING POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.Consuming alcohol and/or...

34 Safety Operator Safety WARNING POTENTIAL HAZARDTowing or pulling an object behind the ATV.WHAT CAN HAPPENA wagon, sled or other object towed behind an ATV does not have brakes or steering. The object may overturn or collide with other objects and cause serious injuries.HOW TO AVOID THE HAZARDNeve...

35 Safety Operator Safety WARNING POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caut...

36 Safety Operator Safety WARNING POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or...

37 Safety Operator Safety WARNING POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds be...

38 Safety Operator Safety WARNING POTENTIAL HAZARDRemoving hands from the handlebars or feet from the footpegs during operation.WHAT CAN HAPPENRemoving even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.If the operator's foot is n...

39 Safety Operator Safety WARNING POTENTIAL HAZARDOperating on excessively steep hills.WHAT CAN HAPPENThe vehicle may overturn.HOW TO AVOID THE HAZARDNever operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees 25 ° . >25 °

40 Safety Operator Safety WARNING POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the Owner's Manual beginning on page 82.Always check the...

41 Safety Operator Safety WARNING POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special tech...

42 Safety Operator Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you've mastered the turning t...

43 Safety Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill. Apply the f...

44 Safety Operator Safety WARNING POTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENSkidding or sliding can cause loss of control.If the tires regain traction unexpectedly, the ATV could overturn.HOW TO AVOID THE HAZARDOn slippery surfaces such as ice, travel slowly and use extra caution to reduce ...

45 Safety Operator Safety WARNING POTENTIAL HAZARDOperating on frozen bodies of water.WHAT CAN HAPPENSevere injury or death can result if the ATV and/or the operator fall through the ice.HOW TO AVOID THE HAZARDNever operate the ATV on a frozen body of water. WARNING POTENTIAL HAZARDOperating this AT...

50 Features and Controls Start Button Engine Stop Switch Main Key Switch

51 Features and Controls Main Key Switch The main key switch must be in the RUN position to start the engine. See page 75 for starting procedures. Start Button Press the start button to engage the starter. Always release the start button promptly when the engine starts. NOTE: If the starter fails to...

52 Features and Controls Lights Indicator Lights An illuminated light in the indicator window will alert you to the follow- ing conditions.• Hot engine• Reverse gear is selected• Neutral gear is selected NOTE: If indicator lights fail to oper- ate, check connections. See your Polaris dealer for insp...

53 Features and Controls Lights Headlights Use the light switch to turn the lights on and off and to switch the lights from high beam to low beam. NOTE: The lights won't work unless the key is in the ON position and the engine stop switch is in the RUN position. WARNING Operating the ATV on streets ...

54 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.The clutch is self-adjusting, but lever position can be changed to fit the operator’s h...

55 Features and Controls 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 ...

56 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. Engine speed returns to idle when the lever is released. See page 159 for throttle adjustment procedures. NOTE: Fuel is ...

57 Features and Controls Throttle Lever This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open posi- tion when the operator releases the throttle lever, the engine will stop. WA...

58 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...

59 Features and Controls Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar.Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes.Always test brake lever travel and master ...

60 Features and Controls Master Cylinder/Brake Fluid Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever...

61 Features and Controls Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder before each ride. If the fluid level is low add DOT 4 brake fluid only. Do not overfill. See page 188 for the part numbers of Polaris prod- ucts. NOTE: When checking the fluid level, the master cylinder...

62 Features and Controls Parking Brake 1. Place the transmission in first gear. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock down to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release...

63 Features and Controls Parking Brake Important Safeguards • The parking brake may relax if left on for a long period of time. Always block the wheels 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...

64 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 ...

65 Features and Controls Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral.2. Squeeze and hold the brake lever. NOTE: Do not squeeze the throttle lever. 3. Squeeze the clutch leve...

66 Features and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally.1. Place the transmission in first gear. See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3. Shif...

67 Features and Controls Manual Shift Deceleration To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased ...

68 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 75 for correct choke and throttle settings during starting. Fuel Tank The fuel tank filler cap is located directly ...

69 Features and Controls Fuel Valve The fuel valve is located on the left side of the ATV. It has three positions:OFF: For vehicle storage and when transporting.ON: For normal operation.RES: For reserve supply if main supply is exhausted. NOTE: There's about a 5 to 8 mile (8 to 13 km) range on reser...

70 Break-In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris ATV is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engi...

72 Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Pre-Ride Checklist Page Brake systems / lever travel Ensure proper operation 58-63 160-161 ...

74 Operation Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline.• Always refuel with the engine stopped, and outdoors or in a well ventilated area.• Do not smoke or allow open flames or sparks in or nea...

75 Operation Starting the Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the ...

76 Operation Starting the Engine 1. Shift the transmission to neutral.2. Lock the parking brake.3. Turn the fuel valve on.4. Sit on the vehicle.5. Disengage the clutch.6. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine. 7. Move the engine...

77 Operation Starting the Engine NOTE: If starting the engine while in gear, apply the hand brake and squeeze the clutch lever fully to disengage the clutch. If starting the engine while in neutral, the neutral indicator light should be on. If it isn't, disengage the clutch and shift the foot pedal ...

78 Operation Driving Procedure 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up.3. Shift the transmission into gear. See page 64.4. Check your surroundings and determine your path of travel. 5. Release the parking brake.6. Sl...

79 Operation Making Turns Practice making turns at slow speeds before attempting to turn at faster speeds. 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 turni...

80 Operation Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death.Never apply the brakes during a skid. Do not operate on excessively slippery surfaces.Al...

82 Operation Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death.Avoid climbing steep hills (25 ° maximum). Use extreme caution when operating on hills, and ...

83 Operation Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 ° maximum). 3. Keep both feet on the footpegs.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be pr...

84 Operation Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.

85 Operation Driving Across Hillsides If you enter into a situation where sidehilling is unavoidable, follow these precautions:1. Slow down.2. Lean into the hill, transferring your upper body weight uphill while keep- ing your feet on the footpegs. 3. Steer slightly into the hill to maintain directi...

86 Operation Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary to turn around while climbing a hill is the K-turn:1. Keep your body weight uphill.2. Pull in the clutch lever and apply the front and rea...

88 Operation Driving Downhill Whenever descending a hill, follow these precautions:1. Drive directly downhill.2. Transfer your weight to the rear of the vehicle. 3. Slow down.4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid in slowing. WARN...

89 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...

90 Operation Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs. Follow these proce- dures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual ...

91 Operation Driving Through Water Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in deeper water than recommended, it's critical to have it serviced as outlined in the mainte- nance chart beginning on page 97. Engine oil and all grease fittings need special atte...

92 Operation Driving in Reverse Follow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles.4. Always avoid backing downhill.5. Never open the throttle suddenly while backing. 6. Always look left, right and behind the AT...

93 Operation Driving in Reverse This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use just enough throttle to maintain a desired speed. WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into rever...

94 Operation Driving Over Obstacles Be alert! Look ahead and learn to read the ter- rain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hang- ing branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obs...

95 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 CFR 205) and local noise level require- ments. Operation on Public Lands in the U.S.A. Your Polaris vehic...

96 Emission Control Systems Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from th...

97 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...

99 Maintenance Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often under severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these se...

100 Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks See Page Hours Calendar Fuel Used Brake systems/brake fluid -- Pre-ride -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist. 72 Tires -- -- Wheels/l...

108 Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke ma...

109 Maintenance Engine Oil Level Check the oil level before each 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 ...

110 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Perform the initial break-in oil change after the first three hours of operation. Always change both oil filters and clean the oil screens whenever changing oil. ...

111 Maintenance Engine Oil Change 1. Position the vehicle on a level surface. NOTE: Remove the skid plate for better access to the oil drain plug and short screen. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Place a drain pan beneath the crankcase. Remove the ...

112 Maintenance Engine Oil Change Cleaning the Short Oil ScreenNOTE: Remove the skid plate for better access to the oil drain plug and short screen. Hex Plug View from bottom of vehicle Front

113 Maintenance Engine Oil Change Cleaning the Short Oil Screen 1. Remove the plug at the bottom of the engine. See illustration on preceding page.2. Remove the short oil screen from the plug. Clean the screen components thoroughly and blow well with compressed air. 3. Check the O-rings. If damaged,...

114 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 the O-rings. If damaged, install new O-rings. 4. Place...

115 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. 6. Reinstall the plug. Torque to 11 ft. lbs. (15 Nm). CAUTION An improp...

116 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 c...

118 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 e...

119 Maintenance Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL and ADD marks on the side panel (when the fluid is cool).As coolant operating temperature increases, the exp...

120 Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dry, inspect the level in the radiator and add coolant if necessary. The radiator pressure cap is located on the left side of the vehicle.1. Remove the pressure cap.2. Using a funnel, slowly add coolant as ne...

121 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- sure cap.1. Remove the pressure cap.2. Using a funn...

122 Maintenance Air Filter Systems NOTE: Refer to the illustrations on page 123. 1. Remove the seat.2. Release the airbox cover clips and remove the cover.3. Loosen the filter clamp. Remove the air filter from the box.4. Locate the retaining spring.5. Carefully remove the retaining spring from the f...

124 Maintenance Carburetor Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and the needle jet after every 180 hours of operation. Idle Speed Carburetor idle adjustments affect engine starting behavior. A proper idle speed of 1...

125 Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool.1. Turn the fuel valve off.2. Place ...

126 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 ...

128 Maintenance Lights Headlight Adjustment 1. Position the vehicle on a level surface with the head- light approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and tur...

129 Maintenance Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb. 3. Apply ...

130 Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp. 5. Install the new head...

131 Maintenance Lights Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. Adjust for approximately 1/16" clearance between the bracket and the edge of the headlight. Tighten the mounting screws. IMPORTANT: Be sure the bracket is 90 degrees ...

132 Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle.1. Turn the ignition key on.2. Lightly apply and release the foot brake several times. A properly operating rear brake light will immedi- ately flash on and off with each move...

133 Maintenance Front Cab Removal 1. Remove the left and right cab mount screws (1).2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2).4. Remove the four side panel screws (3).5. Gently pull the cab upward to di...

134 Maintenance Side Panel Removal 1. Unlatch and remove the seat.2. Remove the front cab.3. Remove the screw securing the side panel.4. Remove the side panel. Side Panel Screw

135 Maintenance Rear Cab Removal 1. Unlatch and remove the seat.2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove the cab. 1 3 2

136 Maintenance Spark Plugs Refer to the specifications section beginning on page 186 for recommended spark plug type and gap. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been drive...

137 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insul...

138 Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right side of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm). Spark Plug

139 Maintenance Spark Arrestor Clean-Out To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 97. WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or dea...

140 Maintenance Spark Arrestor Clean-Out NOTE: Refer to the illustration on page 141. 1. Remove the retaining screw and remove the arrestor from the end of the muffler.2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. NOTE: If necessary, bl...

141 Maintenance Spark Arrestor Clean-Out Arrestor Retaining Screw Screen Muffler

142 Maintenance Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it's critical to dry it promptly and properly before starting the engine. Do not perform the following procedures if you don't feel completely capable, or if you sus- pect that wate...

144 Maintenance Vehicle Immersion 6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride inspection level, water has entered the crankcase....

145 Maintenance Battery 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 t...

146 Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to main...

147 Maintenance Battery Installation NOTE: Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger. 1. Place the b...

148 Maintenance Battery Charging (Sealed Battery) On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is less than 12.8 volts, recharge the battery.The battery may be rec...

149 Maintenance Battery Charging (Sealed Battery) When using an automatic charger such as the Polaris Battery Tender, refer to the manufac- turer's instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging. WARNING An overheated batte...

150 Maintenance Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 months...

151 Maintenance Tires Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. WARNING 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 ...

152 Maintenance Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loosened for maintenance. Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Po...

153 Maintenance Wheel Installation 1. Place the transmission in gear. Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. 3. Install the wheel bolts and finger tighten them.4. Lower the ve...

154 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, perfor...

155 Maintenance Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from...

156 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Maintenance Chart beginning on page 97. Always bleed the clutch system any time the clutch lever feels unresponsive.Always use the recommended fluid when bleeding the clutch system. See ...

157 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. NOTE: Extract fluid from the master cylinder during the process to prevent overflo...

158 Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm).If adjustments are needed, use the procedure on page 159. 1/16 " - 1/8" (1.5 - 3 mm)

159 Maintenance Throttle Cable Freeplay Adjustment 1. Locate the throttle cable at the handlebar.2. Slide the boots off the inline cable adjuster sleeve and loosen the locking nut. 3. Turn the adjuster until 1/16" to 1/8" (1.5-3 mm) freeplay is achieved at the thumb lever. NOTE: While adjust...

160 Maintenance Brakes Both brakes are self-adjusting, but the following checks are recommended to keep the brake systems in good operating condition. Check more often if brakes are used heavily under nor- mal operation. WARNING An over-full master cylinder may cause brake drag or brake lock-up, whi...

161 Maintenance Brakes 1. Always maintain brake fluid at the recommended level. See pages 60-61. 2. Check the brake system for fluid leaks.3. Check the brakes for excessive travel or spongy feel.4. Check the friction pads for wear, damage and looseness.5. Check the security and surface condition of ...

162 Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting.1. Position the vehicle on a level surface.2. Place the handlebars in a straight-ahead position. Use tie straps to secure the handlebars to the rear ...

163 Maintenance Toe Alignment 4. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle. 5. Measure the distance between the string in front of the rear tires (1) a...

164 Maintenance Chain Tension Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. At the center point of the top side of the chain there should be 1/4"-3/8" (6-9 mm) deflection.Use the procedure on the following page if the cha...

165 Maintenance Chain Tension 1. Loosen the upper and lower pivot mounting bolts (1).2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm).4. Torque the chain adjusting bolt to 17 ft. lbs. (2...

166 Maintenance Handlebar Adjustment 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. To...

167 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 camber and caster are ...

168 Maintenance Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Meas...

169 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 vehicl...

170 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 handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the le...

171 Maintenance Front Suspension Spring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Loosen the jam nut.3. Turn the adjusting ring clockwise to increase preload (1). Turn the ring counter-clockwise to decrease preload (2). 4....

172 Maintenance Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the rear of the vehicle by plac- ing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Meas...

174 Maintenance Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the soft- est position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments. Rear Shock Setting Compression Dam...

175 Maintenance Rear Suspension The rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the vehicle off the ground to allow the suspension t...

176 Maintenance Rear Suspension Compression Damping The compression damping clickers are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments.To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From this p...

177 Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, ...

178 Maintenance Cleaning Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently.3. Dry su...

180 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 • Avoid the use of automotive products, some of which can scratch the finish of your vehi- cle....

181 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 177. Battery Storage Refer to pages 145-150 for battery storage and battery charging procedures. CAUTION Starting the engine during the storage period will disturb the protective film created by fo...

182 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 110. Air Filter / Air Box Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic Mai...

183 Maintenance Storage Stabilize the Fuel 1. Fill the fuel tank with fuel.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc- tions on the container for the recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes car...

184 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 97. Storage Area/Covers 1. Make sure tire pressure is at specification.2. Be sure the storage area is well ventilated.3. Using suitable sup...

185 Maintenance Transporting the ATV Follow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in first gear.3. Lock the parking brake.4. Remove the key to prevent loss during transporting.5. Secure the fuel cap, oil cap and seat.6. Turn the fuel valve off.7....

186 Specifications Outlaw 525 IRS Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45 Dry Weight 395 lbs./179 kg Main Jet 148 Fuel Capacity 3.9 gal./14.8 l Needle Jet OBDVS Overall Length 71.5 in./182 cm Needle Clip #4 Overall Width 47.5 in./121 cm Slow Air Jet 100 Overall Height 45 in./114 cm Altern...

187 Specifications Jetting Chart Outlaw 525 IRS Driving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10 Shift Type 5-Speed Manual Shift Tire Size - Rear 20 x 10R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dual Bore Gear Rat...

188 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...

189 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.)

190 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...

192 Troubleshooting Engine Doesn’t Turn Over Engine Pings or Knocks Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections a...

193 Troubleshooting Engine Backfires 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...

194 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 igni...

196 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 scre...

197 Troubleshooting Engine Fails to Reach High RPM Engine Uses Excessive Oil Possible Cause Solution Worn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets Tighten jets Faulty ignition timing See your Polaris dealer Possible Cause Solution Bent engine ventilation hose Ins...

198 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 d...

200 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 coola...

201 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 Val...

202 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 f...

203 Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This ...

205 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 F...

206 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 expo...

207 Warranty EXPORTED VEHICLES How to Get Service I n 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 repair...

208 Warranty EXPORTED VEHICLES How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...

209 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...

211 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 3...

215 Index A Age Restrictions . . . . . . . . . . . . . . 14 Air Filter Systems . . . . . . . . . 122-123 B Battery Charging. . . . . . . . . . . . 148-150 Installation . . . . . . . . . . . . . 147 Maintenance . . . . . . . . . . . . 145 Removal . . . . . . . . . . . . . . . 146 Storage . . . . . . ...

216 INDEX F Fluid Brake . . . . . . . . . . . . . . . . 60-61 Clutch . . . . . . . . . . . . . . . . . . 55 Foot Brake . . . . . . . . . . . . . . . . . . . 58 Foot Brake Fluid Level . . . . . . . . . 61 Fuel Filter . . . . . . . . . . . . . . . . . . . . 68 Fuel Stabilizer . . . . . . . . . . . . ....