Polaris 525 IRS - Manual

Polaris 525 IRS

Polaris 525 IRS – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 3 – WARNING; The engine exhaust from this
  • Page 6 – Welcome; RANGER
  • Page 7 – ered right to your door!
  • Page 8 – Table of Contents
  • Page 9 – Know Your Vehicle; The high performance engine in your vehicle; Vehicle Identification Numbers; keys. The ignition switch must be replaced if all keys are lost.
  • Page 11 – Safety Decals; safety
  • Page 12 – General Warning
  • Page 13 – Age 16 Warning
  • Page 14 – No Passenger Warning; in SEVERE INJURY or DEATH.; Tire Pressure/Load Warning; OVERLOADING can cause loss of control,; Tire Pressure
  • Page 15 – Safety; Riding Gear; Helmet
  • Page 16 – Eye Protection; pads and a jersey with shoulder pads provide the best protection.
  • Page 17 – Operator Safety; Operator Restrictions/Age Restrictions; skills and substantial experience.
  • Page 18 – Safety Training; RiderCourse
  • Page 19 – meanings before reading the manual.; The; CAUTION; CAUTION; caution
  • Page 20 – Take a training course.; outlined in further detail within your owner's manual.
  • Page 26 – Equipment Modifications
  • Page 27 – offered by Polaris through the SVIA. They should then
  • Page 29 – substantial experience should operate this ATV.
  • Page 30 – balance and control the ATV, which could cause an accident and
  • Page 31 – surfaces may adversely affect the handling of the ATV and
  • Page 32 – highway, including dirt and gravel roads. In many states
  • Page 33 – the risk of a severe head injury or death in the event of
  • Page 34 – operator judgment. Reaction time may be slower and operator
  • Page 37 – does not have brakes or steering. The object may
  • Page 38 – unfamiliar terrain. Always be alert to changing terrain
  • Page 39 – could cause loss of traction or loss of control, which
  • Page 40 – as described in the owner's manual. Practice; check for obstacles or people behind the ATV.
  • Page 41 – control the vehicle or could cause loss of balance and
  • Page 42 – your abilities. Never operate the ATV on hills steeper
  • Page 43 – Never operate the ATV on hills steeper than 25 degrees
  • Page 44 – technique is required when braking while traveling downhill.
  • Page 45 – POTENTIAL HAZARD; Improperly crossing hills and turning on hills.; WHAT CAN HAPPEN; Improperly crossing or turning as hills could cause loss of; HOW TO AVOID THE HAZARD; Never try to turn the ATV around on any hill until you've
  • Page 46 – If all forward speed is lost:
  • Page 47 – and use extra caution to reduce the chance of; rocks and fallen trees when possible. If
  • Page 48 – with improper or uneven tire pressure, could
  • Page 53 – Features and Controls; Start Button
  • Page 54 – Main Key Switch; Move the stop switch either left or right to the OFF; Both the main switch and the engine stop switch; OFF
  • Page 55 – Lights; Indicator Lights; An illuminated light in the indicator; If indicator lights fail to oper-; Reverse
  • Page 56 – Headlights; Use the light switch to turn the lights on and off; The lights won't work unless the key is in the; reduced visibility such as fog, rain and darkness.
  • Page 57 – Clutch Lever; Adjusting Knob
  • Page 58 – Clutch Fluid; Do not use brake fluid. Do not mix; Screws
  • Page 59 – The throttle lever is located on the right handlebar.; Fuel is injected into the intake passage each time; starting the engine. Also check occasionally during operation.; Throttle Lever
  • Page 60 – market throttle mechanism.
  • Page 61 – Foot Brake; loss of control and serious injury or death.; Footpeg
  • Page 62 – accident. Never operate the ATV with a spongy-feeling brake lever.; Hand Brake
  • Page 63 – Master Cylinder/Brake Fluid; removed to ensure proper diaphragm operation. Do not overfill.; opening a bottle of brake fluid, always discard any unused portion.
  • Page 64 – Hand Brake Fluid Level; Fluid Level Mark
  • Page 65 – Parking Brake; Locked
  • Page 66 – Important Safeguards
  • Page 67 – Manual Shift; Shift Pedal; throttle and fully squeeze the clutch lever while shifting gears.; Upshift
  • Page 68 – Shifting Gears; Always allow a cold engine to warm up before shifting gears.
  • Page 69 – Reverse Lock-Out Switch; The reverse lock-out switch prevents the; The lock will automatically re-engage
  • Page 70 – Deceleration
  • Page 71 – Choke; Choke Knob
  • Page 72 – Fuel Valve; The fuel valve is located on the left side of the ATV. It; reserve gas. Always refill the gas tank as soon as; Always return the valve to the ON position after refueling.
  • Page 73 – recommended oil. Never substitute or mix oil brands.
  • Page 75 – Page
  • Page 77 – Operation; Fuel System; where gasoline is stored.
  • Page 78 – Starting the Engine; up for several minutes before operating.
  • Page 79 – choke knob out until it stops. Do
  • Page 80 – onds. Release the start button immediately when the engine starts.; Excessive engagement may result in starter damage.
  • Page 81 – Driving Procedure; Sit upright with both feet on the footpegs and
  • Page 82 – Making Turns
  • Page 83 – Driving on Slippery Surfaces
  • Page 85 – Driving Uphill
  • Page 86 – Whenever traveling uphill, follow these
  • Page 87 – Driving Across Hillsides
  • Page 88 – upper body weight uphill while keep-; If the vehicle begins to tip, quickly
  • Page 89 – Turning Around on a Hill; the clutch lever and lock the parking brake.
  • Page 91 – Driving Downhill; Whenever descending a hill, follow these; slowly when traveling downhill.
  • Page 92 – Parking on a Hill or Incline; Avoid parking on a hill or incline if pos-
  • Page 93 – Driving Through Water; Maximum Depth
  • Page 94 – turns or stops, and do not make sudden throttle changes.
  • Page 95 – Driving in Reverse; Follow these guidelines when operating in
  • Page 96 – just enough throttle to maintain a desired speed.; procedures outlined in this manual.; resulting in engine popping and/or engine damage.
  • Page 97 – Driving Over Obstacles; Be alert! Look ahead and learn to read the ter-; Severe injury or death can result if your vehicle
  • Page 98 – Emission Control Systems; Noise Emission Control System
  • Page 99 – Crankcase Emission Control System
  • Page 100 – Maintenance; Periodic Maintenance Chart; Severe Use Definition
  • Page 102 – Maintenance Chart Key; Perform these operations more often under severe use.; Improperly performing the procedures marked with a
  • Page 103 – Item
  • Page 111 – Engine Oil Recommendations; PLUS; Do not use Polaris PS-4
  • Page 112 – Engine Oil Level; Sight Glass
  • Page 113 – Engine Oil Change
  • Page 114 – Position the vehicle on a level surface.; Remove the skid plate for better access to the; Start the engine. Allow it to idle for two to three; Hot oil can cause serious burns to skin. Do not; Drain Plug
  • Page 115 – Hex Plug; View from bottom of vehicle
  • Page 116 – Cleaning the Short Oil Screen; blow well with compressed air.
  • Page 117 – Cleaning the Long Oil Screen; on the side of the engine near the engine; Plug
  • Page 118 – An improperly installed oil screen will
  • Page 119 – Changing Oil Filters; Thoroughly clean the engine casing, filter
  • Page 121 – Engine Cooling System; for the part numbers of Polaris products.
  • Page 122 – Coolant Level; Some coolant level drop on new machines is; ADD
  • Page 123 – Radiator Coolant Level; If the recovery bottle has run dry, inspect the level in the; Contact your dealer for the correct replacement part.; or hot. Always allow the engine to cool before removing the cap.; Pressure
  • Page 124 – Cooling System Bleeding; level in the radiator. Add coolant as needed.
  • Page 125 – Air Filter Systems; Refer to the illustrations on page 123.
  • Page 127 – Carburetor; Idle Speed; Carburetor idle adjustments affect engine starting; information about jetting changes.
  • Page 128 – Carburetor Draining; Drain the carburetor float bowl at the intervals outlined in the
  • Page 129 – Carburetor Jetting; required to perform these modifications.
  • Page 131 – Headlight Adjustment; Include rider weight on the seat when measuring.; Pivot
  • Page 132 – Headlight Lamp Replacement; counterclockwise; The bulb must be positioned so the; Left Lamp
  • Page 133 – Headlight Assembly Replacement; Remove the wire harness connector from the; Small Adjuster
  • Page 134 – Tighten the mounting screws.
  • Page 135 – Brake Light Adjustment; comes on when there is no pressure on the brake pedal.; Switch
  • Page 136 – Front Cab Removal; The connector is located under the left fender.
  • Page 137 – Side Panel Removal; Side
  • Page 138 – Rear Cab Removal; rear fenders of the cab.
  • Page 139 – Spark Plugs; speeds. Immediately check the spark plug for correct color.
  • Page 140 – Normal Plug; engine and the service.; Wet Fouled Plug; rect carburetion adjustments.
  • Page 141 – Spark Plug Removal; Access the spark plug at the right side of the; Spark
  • Page 142 – Spark Arrestor Clean-Out; Periodic Maintenance Chart beginning on page 97.; can cause loss of consciousness or death in a very short time.
  • Page 143 – Refer to the illustration on page 141.; components are warm.; If necessary, blow debris from the screen with compressed air.
  • Page 144 – Arrestor
  • Page 145 – Vehicle Immersion; turned). Tow or trailer the ATV to your dealer for immediate service.; operation only
  • Page 147 – water vapor is no longer ejecting from the spark plug hole.; dealer promptly after an ATV has been submerged.
  • Page 148 – Battery; Never
  • Page 149 – Battery Storage
  • Page 150 – Battery Installation
  • Page 151 – it from the vehicle. Use the remote charging ter-; Charging
  • Page 152 – on the following page for recharging.
  • Page 153 – State of
  • Page 154 – Tires; Always replace tires when tread depth is
  • Page 155 – Wheel Nut Torque Specifications; All service must be performed by your authorized Polaris dealer.; Wheel Removal; Torque Specification
  • Page 156 – Wheel Installation; Place the transmission in gear. Lock the parking; ensure that all nuts are torqued to specification.; Valve
  • Page 157 – Boot Inspection; Before Operating; Inspect the boots before operating the vehicle. If a boot is; After Operating; Inspect the boots after operating the vehicle. If a boot is; Good Boot
  • Page 158 – Boot Burping; Do not use any tools that may damage the boot.
  • Page 159 – Clutch System Bleeding
  • Page 160 – without producing bubbles.
  • Page 161 – Throttle Lever Freeplay; Periodically check throttle lever freeplay.
  • Page 162 – Throttle Cable Freeplay Adjustment; sleeve and loosen the locking nut.; While adjusting freeplay, be sure to flip the; midpoint of the adjuster.; must follow the adjustment procedures exactly.; Boot
  • Page 163 – Brakes
  • Page 164 – Always maintain brake fluid at the recommended level. See
  • Page 165 – Toe Alignment
  • Page 166 – If you discover improper alignment, see your; Stands
  • Page 167 – Chain Tension; Check the amount of chain slack by moving; chain tool must be used if it's necessary; to the transmission and drive components can result.
  • Page 168 – Proper splicelink clip
  • Page 169 – Handlebar Adjustment; handlebars do not contact the gas tank or any other part; Loosen
  • Page 170 – Steering Inspection; before operating the vehicle.; Camber and Caster; The camber and caster are non-adjustable.
  • Page 171 – Front Suspension; The tires should be barely touching the
  • Page 172 – decrease
  • Page 173 – Spring Preload; Polaris dealer perform the adjustments.
  • Page 174 – Raise and safely support the front of the vehicle; Adjusting
  • Page 175 – Rear Suspension; ing a suitable stand under the frame.; Measure the distance from the ground
  • Page 177 – Use a flat blade screwdriver to make damping adjustments.; Rear Shock; Setting; Softest
  • Page 178 – The rear suspension spring preload, shock rebound; Raise and safely support the rear of the vehicle off
  • Page 179 – Compression Damping; The compression damping clickers are located on the; Clicker
  • Page 180 – Cleaning; life of various components.; allow these types of products to contact the vehicle.
  • Page 181 – Washing the Vehicle; Washing Tips; pads may contain dirt particles that will scratch the finish.
  • Page 183 – Polishing; Polishing Tips
  • Page 184 – Storage; Exterior
  • Page 185 – Engine Oil; Change the oil and both filters. Clean the oil screens. See page 110.; Fluid Levels
  • Page 186 – Stabilize the Fuel; tions on the container for the recommended amount.; motes better starting after the storage period.; through the fuel in the tank and carburetor.
  • Page 187 – Lubricate; tenance Chart beginning on page 97.; densation, and may promote corrosion and oxidation.
  • Page 188 – Transporting the ATV; frame
  • Page 189 – Specifications
  • Page 190 – Jetting Chart; ALTITUDE
  • Page 191 – Polaris Products; Part Number; Engine Lubricant; Dielectric Grease (Nyogel
  • Page 192 – Coolant
  • Page 193 – Troubleshooting; Engine Turns Over, Fails to Start; Possible Cause
  • Page 195 – Engine Doesn’t Turn Over
  • Page 196 – Engine Backfires
  • Page 197 – Engine Runs Irregularly, Stalls or Misfires
  • Page 199 – Possible Lean Fuel Mixture Cause
  • Page 200 – Engine Fails to Reach High RPM
  • Page 201 – Engine Stops or Loses Power
  • Page 203 – Engine Overheats
  • Page 204 – Engine Fails to Reach Full Power
  • Page 205 – Warranty; LIMITED WARRANTY; through a Polaris dealer.; REGISTRATION
  • Page 206 – WARRANTY COVERAGE AND EXCLUSIONS:; LIMITATIONS OF WARRANTIES AND REMEDIES
  • Page 208 – HOW TO OBTAIN WARRANTY SERVICE; with Polaris recommendations.
  • Page 209 – EXPORTED VEHICLES
  • Page 210 – How to Get Service; n the country where your vehicle was purchased:
  • Page 211 – If Purchased From A Private Party:; Notice; For questions call Polaris Customer Assistance:
  • Page 212 – recommended maintenance.
  • Page 214 – Maintenance Log
  • Page 218 – Index
  • Page 219 – INDEX
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Summary

Page 3 - WARNING; The engine exhaust from this

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. WARNING The engine exhaust from this product contains chemicals known to the State of Ca...

Page 6 - Welcome; RANGER

3 Welcome Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER utility vehicles • Victory motorcycles

Page 7 - ered right to your door!

4 Welcome We believe Polaris sets a standard of excellence for all utility and recreational vehicles man- ufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.For safe ...

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