Polaris 450 MXR - Manual

6 Introduction Safety Words and Symbols 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 indicates a potentia...

8 Introduction 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 o...

10 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. Polaris strong...

12 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 modifications to the veh...

13 Safety 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...

14 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 markin...

15 Safety Safety Warnings 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 pr...

16 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...

17 Safety 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 ventilated area. • Do not smoke or allow open flames or sp...

18 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 inspecti...

19 Safety Safety Warnings Carrying a Passenger Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV. Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could...

20 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 de...

21 Safety Safety Warnings Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience. Physical Control of the ATV Remov...

22 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 ...

23 Safety Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 72. Operating on Steep Hills Operating on excessively steep hills could cause an overturn. ...

24 Safety 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...

25 Safety 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 t...

26 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 hill. If all forward speed is lost Keep body weight uphill. Apply the front brakes gradually (ri...

27 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 ...

28 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 c...

29 Safety 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...

30 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 footp...

31 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 reduc...

32 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 ...

33 Safety 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 caution when traveling th...

34 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 ...

35 Safety Safety Labels and Locations 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 instruc...

36 Safety Safety Labels and Locations 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. 7175374 Discretionary/Sport ATV Warning WARNING• Never operate this ATV on HILLS steeper than ...

37 Safety Safety Labels and Locations No Passenger Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control.Loss of control can resul...

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

39 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 engag...

40 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 selectedIf indicator lights fail to operate, check connections. See your Polaris dealer for inspection of...

41 Features and Controls Lights Headlights Use the headlight switch to turn the lights on and off and to change 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

42 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...

43 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 ...

44 Features and Controls Throttle Lever 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...

45 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 each time throttle is applied. Do not squeeze the throt- tle lever while startin...

46 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...

47 Features and Controls 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 maste...

48 Features and Controls Master Cylinder/Brake Fluid 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, m...

49 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 172 for the part numbers of Polaris prod- ucts. Hand Brake Fluid Level 1. Position the ATV on a level su...

50 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 ...

52 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 ...

53 Features and Controls Manual Shift Shifting Gears 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. Do not apply throttle. 3. Squeeze the clutch lever to disengage the clutc...

54 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...

55 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 speed decreases, disengage the clutch and shift to a lower gear. Be sure engine speed has sufficiently decreased before...

56 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 ...

57 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 exhau...

58 Operation 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. 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 ...

60 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 En...

62 Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 10. 2. 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. 3. Never carry a ...

64 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 r...

65 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 ...

66 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 throttl...

68 Operation Driving Procedures 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 trave...

69 Operation 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 turn- ing, and the inside tire slips traction slightly.To turn, steer in the direction...

70 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. Do not operate on excessively rough, slip- pery or loose terrain. 2. Slow down when entering slippery areas.3. Maintain a high le...

71 Operation 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. Sideways skid Turn in direction of skid

72 Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions:1. Drive straight uphill.2. Avoid steep hills (25 ° maximum). 3. Always check the t...

73 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...

74 Operation Driving on a Sidehill (Sidehilling) 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 sidehill is unavoidable , follow these precautions: 1. Slow down.2. Lea...

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 t...

77 Operation Turning Around on a Hill 9. Pull in the clutch lever, shift into neutral and restart the engine.10. Release the parking brake and slowly release the clutch lever, allowing the ATV to pro- ceed slowly. Stay in first gear, using the brakes for additional speed control if necessary, until ...

78 Operation Driving Downhill When driving downhill, 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 traveling downhill can cause loss of control....

79 Operation Parking on a Hill or Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precau- tions:1. Stop the engine.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 ...

80 Operation Driving Through Water Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions 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 bo...

81 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...

82 Operation Driving in Reverse Follow these precautions when operat- ing in reverse:1. Always check for obstacles or peo- ple behind the vehicle. 2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stop- ping. 5. Avoid turning at sharp angles.6. Never open the throttle s...

84 Operation Driving Over Obstacles Follow these precautions when operating over obstacles:1. Always check for obstacles before oper- ating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and u...

85 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...

86 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 performanc...

87 Maintenance Periodic Maintenance Chart Routine inspection and service are critical to the performance and reliability of your high performance engine. Failure to perform the recommended maintenance procedures outlined in the Periodic Maintenance Chart will result in forfeited warranty coverage as...

88 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• ...

89 Maintenance Periodic Maintenance Chart Improperly performing the procedures marked with a Q 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 X Perform these ...

90 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. 60 Tires -- -- Wheels/lu...

98 Maintenance Engine Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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 man...

99 Maintenance Engine Oil Level Check the oil level before each use of the vehi- cle. 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 between the 1/2 and 3/4 levels in the sight glass.1. Position the ...

100 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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. ...

101 Maintenance Engine Oil Change 1. Position the vehicle on a level surface.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 drain plug. Allow the oil to drain completely. CAUTION! Hot oil can cause burns to skin....

102 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Short Oil Screen Plug View from bottom of vehicle Front O-Rings

103 Maintenance Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine.2. Remove the short oil screen. Clean the screen components thoroughly and blow well with low pressure compressed air. 3. Check the O-rings. If damaged, install new O-rings...

104 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...

106 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...

108 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...

109 Maintenance 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 increases, the expanding (heated...

110 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. CAUTION! Escaping steam can cause burns. Never remove the pressure ca...

111 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...

112 Maintenance Air Filter Systems 1. Remove the seat.2. Release the airbox cover clips and remove the cover.3. Remove the wing nuts securing the filter to the airbox.4. Pull the filter assembly out of the air box. Note the placement of the rubber ring for rein- stallation. 5. Wash the filter in soa...

113 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...

114 Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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 ...

115 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 ...

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

117 Maintenance Lights Headlight Adjustment 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Include rider weight on the seat when measuring. 5. Loosen the pivot screw and adjust the beam to the des...

118 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 lamp, clean it with denatured alcohol.1. Remove the wire h...

119 Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover.2. Remove the wire harness connector from the headlight.3. Remove the two retaining brackets and the adjuster screw.4. Remove the headlamp.5. Install the new headlamp, placing it in the slots on the frame tabs. Secure th...

120 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 pane...

121 Maintenance Rear Cab Removal 1. Remove the seat.2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts and grommets (2) on the top of the cab. 4. Remove the two bolts (3) at the rear cab-to-front-cab joint. 5. Unplug the taillight connector.6. Remove the cab. 1...

122 Maintenance Spark Plugs Refer to the specifications section beginning on page 168 for recommended 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 opera...

123 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 t...

124 Maintenance Spark Arrestor Clean-Out 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 suffici...

125 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 87.1. Remove the retaining screw and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean...

126 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, restarting WILL result in serious engine damage. Trans- port the vehicle to your dealer for service before restarting the engine. If t...

127 Maintenance Vehicle Immersion 1. Turn the fuel valve off.2. Drain water from the air box and clean the air filter. See page 112.3. Drain the carburetor bowl. See page 114.4. Remove the spark plug. See page 122. WARNING! Fluids will be ejected through the spark plug hole and may cause serious inj...

128 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....

129 Maintenance Battery 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. Th...

130 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...

131 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 ...

132 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 overheate...

133 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 vo...

134 Maintenance Battery Charging (Sealed Battery) 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 from ...

135 Maintenance Tires 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 manua...

136 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...

137 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. Never install the rim with the valve stem to the inside of the veh...

138 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Maintenance Chart beginning on page 87. Always bleed the clutch system any time the clutch lever feels unresponsive.Always use the recommended fluid when bleeding the clutch system. See ...

139 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. Extract fluid from the master cylinder during the process to prevent overflowing. ...

140 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 141. 1/16 " - 1/8" (1.5 - 3 mm)

141 Maintenance 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 a Polaris dealer to ensure that it's done correctly. Mechanically kno...

142 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 ...

143 Maintenance Brakes 1. Always maintain brake fluid at the recommended level. See pages 48-49. 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 ...

144 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 adjus...

145 Maintenance Toe Alignment 3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straight- edge instead of string. 4. Measure the distance from the string to the r...

146 Maintenance Chain Tension Inspection Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. NOTICE: Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive comp...

147 Maintenance Chain Tension Inspection 1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fas- ten the strap around the axle and rear bumper tube. 2. Tighten the strap until a straight line (2) can be drawn from the axle to the transmission output shaft, inters...

148 Maintenance Chain Tension Adjustment 1. Loosen the two eccentric locking bolts. Refer to the illustration on the following page.2. Insert a pin punch into the eccentric axle housing.3. Roll the vehicle slightly to adjust chain slack to the proper dimension.4. Tighten the eccentric locking bolts ...

149 Maintenance Chain Tension Adjustment Step 1 Step 2 Proper splicelink clip opening position

150 Maintenance Handlebar Adjustment 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 se...

151 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 ...

152 Maintenance Suspension Settings Use a flat-blade screwdriver to make damping adjustments. When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. Rear Shock (Standard and Limited Edition) Front Shock (Limited Edition) Setting Compression Damping R...

153 Maintenance Front Suspension Compression Damping (Limited Edition) To adjust the front suspension compression damping, use the adjustment procedures outlined for the rear suspension compression damping on page 157. Spring Preload The front suspension preload may be adjusted to suit different rid...

154 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 and back it away from the adjusting ring. 3. Turn the adjusting ring to the left (1) to increase preload for a stiffer ri...

155 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...

156 Maintenance Rear Suspension Rebound Damping Use a flat-blade screwdriver to make damping adjustments. The rebound damping is factory set at 16 clicks from fully closed. See Suspension Settings on page 152.1. Locate the rebound damping clicker drum between the lower spring seat and the lower shoc...

157 Maintenance Rear Suspension Compression Damping Use a flat-blade screwdriver to make damping adjust- ments. The factory setting is at 10 clicks from fully closed. See Suspension Settings on page 152.The compression damping clicker is located on top of the shock reservoir, under the right rear fe...

158 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, ...

159 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 and polishing. Old or r...

161 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....

162 Maintenance 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 recommended. See page 158. Battery Stor...

163 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 100. 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...

164 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. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon de...

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 87. Storage Area/Covers 1. Make sure tire pressure is at specification.2. Be sure the storage area is well ventilated.3. Using suitable sup...

166 Maintenance Transporting the ATV 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. Always tie the frame of the ATV to the transporting u...

168 Specifications Outlaw 450 MXR Max. Weight Capacity 215 lbs./98 kg Pilot Jet #45 Dry Weight 360 lbs./163 kg Main Jet #138 Fuel Capacity 3.1 gal./11.8 l Clip Position 3 Overall Length 71.5 in./182 cm Jet Needle OBDVR Overall Width 47 in./119 cm Alternator Output 200 w @ 3000 RPM Overall Height 45 ...

169 Specifications Outlaw 450 MXR Jetting Chart Outlaw 450 MXR Driving System Type Rear Two-Wheel Drive Tire Size - Front 20 x 6R10 Shift Type 5-Speed Manual Shift Tire Size - Rear 18 x 10R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dua...

171 Specifications Outlaw 525 S Jetting Chart Outlaw 525 S Driving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10 Shift Type 5-Speed Manual Shift Tire Size - Rear 20 x 11R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Brake Hydraulic Disc, Dual Bo...

172 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...

173 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.)

174 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...

176 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...

177 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...

178 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...

180 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...

181 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...

182 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...

184 Troubleshooting Engine Overheats Possible Cause Solution Debris lodged in radiator 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. Insuffici...

185 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...

186 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...

187 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 ...

189 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...

190 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...

191 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...

192 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...

195 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...

199 Index A Age Restrictions . . . . . . . . . . . . . . 15 Air Filter Systems . . . . . . . . . . . . 112 B Battery Charging. . . . . . . . . . . . 132-134 Installation . . . . . . . . . . . . . 131 Maintenance . . . . . . . . . . . . 129 Removal . . . . . . . . . . . . . . . 130 Storage . . . . . ...