Polaris 2007 Outlaw 525 Page 197 Owner'S Manual Download

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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 ignition connections

Check all connections and tighten

Defective ignition system

See your Polaris dealer

Water present in fuel

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC or replace

Kinked or plugged fuel vent line

Inspect and replace

Old or non-recommended fuel

Replace with recommended fuel

Summary of Contents for 2007 Outlaw 525

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Page 3: ...r 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...

Page 4: ...1 Visit us at www polarisindustries com...

Page 5: ...nd quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication ar...

Page 6: ...ing 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 utili...

Page 7: ...Your manual contains instructions for minor mainte nance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Servic...

Page 8: ...Decals 8 Safety 12 Features and Controls 50 Break In Period 70 Pre Ride Inspection 72 Operation 74 Emission Control Systems 95 Maintenance 97 Specifications 186 Polaris Products 188 Troubleshooting 1...

Page 9: ...about all aspects of your vehicle including safe operating pro cedures Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spa...

Page 10: ...________________________________ Frame Vehicle Identification Number 1 ______________________________________________________ Engine Serial Number 2 ___________________________________________________...

Page 11: ...differ from the decals on your vehicle always read and follow the instructions of the decals on the vehicle If any decal becomes illegible or comes off contact your Polaris dealer to purchase a repla...

Page 12: ...our skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper ri...

Page 13: ...ance vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience 7173837 Discretionary Warning Never operate this ATV on HIL...

Page 14: ...TH TIRE PRESSURE IN PSI KPa FRONT 4 27 6 REAR 4 27 6 MAXIMUM WEIGHT CAPACITY 215 LBS 97 5 KG INCLUDES WEIGHT OF OPERATOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when...

Page 15: ...or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label Th...

Page 16: ...al Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and prot...

Page 17: ...nced skills and substantial experience WARNING Failure to follow the warnings in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicl...

Page 18: ...rials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Expr...

Page 19: ...t symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The s...

Page 20: ...ety org for information on enrollment in the ATV RiderCoursesm Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manua...

Page 21: ...ds Travel at speeds appropriate for the terrain visi bility and operating conditions and your experience Never attempt jumps or other stunts Never tow or pull an object behind the ATV Always inspect y...

Page 22: ...aller hills before attempting larger hills Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose s...

Page 23: ...ned in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed whe...

Page 24: ...es Always follow proper procedures when operating over obstacles as described in this manual Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your w...

Page 25: ...always main tain proper tire pressure Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for your ATV Always remove the ignition key when the...

Page 26: ...ginal equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle...

Page 27: ...situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then re...

Page 28: ...skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators...

Page 29: ...dation operates this ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and co...

Page 30: ...reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of...

Page 31: ...nd driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury...

Page 32: ...streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads...

Page 33: ...et increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the...

Page 34: ...or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV cou...

Page 35: ...speed that s proper for the terrain visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WH...

Page 36: ...NG POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other s...

Page 37: ...n object behind the ATV WHAT CAN HAPPEN A wagon sled or other object towed behind an ATV does not have brakes or steering The object may overturn or collide with other objects and cause serious injuri...

Page 38: ...the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use ext...

Page 39: ...cessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slip...

Page 40: ...described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT...

Page 41: ...e hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could contact the rear...

Page 42: ...IAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the AT...

Page 43: ...ual beginning on page 82 Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees 25 Never climb hills with excessively slippery or loose sur...

Page 44: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 88 Always check the terrain carefully before descend...

Page 45: ...to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 86 Use extra caution when turning on any hill Avoid crossing...

Page 46: ...pply the front brakes gradually right lever When fully stopped apply the foot brake as well and then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine po...

Page 47: ...extra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of contr...

Page 48: ...rozen body of water WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper...

Page 49: ...through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 90 travel slowly balance your weight carefully avoid sudden movements and mai...

Page 50: ...pacity for this ATV WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling...

Page 51: ...te this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death WARNING Operating a damaged ATV can result in an accident with serious injury or dea...

Page 52: ...Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass WARNING Leaving the keys in...

Page 53: ...50 Features and Controls Start Button Engine Stop Switch Main Key Switch...

Page 54: ...art button promptly when the engine starts NOTE If the starter fails to engage replace the blown fuse or see your Polaris dealer Engine Stop Switch Move the stop switch either left or right to the OFF...

Page 55: ...tor 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...

Page 56: ...sition and the engine stop switch is in the RUN position WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death This vehicle is no...

Page 57: ...usting knob counterclockwise to move the lever closer to the handle bar Turn the adjusting knob clockwise to move the lever away from the handlebar NOTE The adjustment range is limited Never apply exc...

Page 58: ...nds the use of KTM Hydraulic Clutch Oil Do not use brake fluid Do not mix clutch fluid with any other hydraulic fluids See page 188 for the part numbers of Polaris products 1 Position the vehicle on a...

Page 59: ...gine Do not squeeze the throttle lever when the engine is stopped WARNING Operating with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death N...

Page 60: ...ottle If the throttle cable should stick in an open posi tion when the operator releases the throttle lever the engine will stop WARNING The Electronic Throttle Control ETC stops the engine in the eve...

Page 61: ...s located under the seat Maintain the fluid level between the minimum and maximum marks Check the rear brake light for proper operation before each use of the vehicle See page 132 WARNING Aggressively...

Page 62: ...t brake lever travel and master cylin der fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylin der fluid level whi...

Page 63: ...on Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfil...

Page 64: ...cking the fluid level the ATV must be on level ground with the handlebars straight Hand Brake Fluid Level View the fluid level through the indicator window on the side of the master cylinder Maintain...

Page 65: ...brake lock down to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The lock will auto matically disengage WARNING Operating the ATV whil...

Page 66: ...to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake al...

Page 67: ...o upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal one full...

Page 68: ...ever to disengage the clutch 4 Depress the gear shift pedal one full stroke to shift into first gear 5 Release the brake lever 6 Gradually squeeze the throttle lever while slowly releasing the clutch...

Page 69: ...m shifting into reverse unintentionally 1 Place the transmission in first gear See page 64 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into reverse g...

Page 70: ...to a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear WARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tire...

Page 71: ...r correct choke and throttle settings during starting Fuel Tank The fuel tank filler cap is located directly below the handlebar Polaris recommends the use of 91 octane or higher fuel Do not use E 85...

Page 72: ...For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the...

Page 73: ...n additional 12 hours of cautious operation with engine speed below 75 of capacity No single action on your part is as important as following the procedures for a proper break in Perform the following...

Page 74: ...operation and handling 5 Vary throttle positions Do not operate at sustained idle 6 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See pa...

Page 75: ...Checklist Page Brake systems lever travel Ensure proper operation 58 63 160 161 Brake fluid Ensure proper level 60 Clutch lever Check for proper operation and adjustment 54 Clutch fluid Ensure proper...

Page 76: ...spect clean replace as needed 122 Air box sediment tubes Drain deposits when visible Headlamp Check operation apply Polaris dielectric grease to the socket when the lamp is replaced 129 Brake light ta...

Page 77: ...refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and chang...

Page 78: ...lever is depressed Do not depress the throttle lever while starting the engine Do not depress the throttle lever when the engine is stopped WARNING Engine exhaust contains poisonous carbon monoxide a...

Page 79: ...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 engi...

Page 80: ...intake passage each time the throttle lever is depressed Do not depress the throttle lever while starting the engine Do not depress the throttle lever when the engine is stopped NOTE Excessive engage...

Page 81: ...arm 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 Slowly depress the throttle with your right thumb while...

Page 82: ...slips traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balanc...

Page 83: ...ting 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...

Page 84: ...l or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause ski...

Page 85: ...hen 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...

Page 86: ...avel 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 prepa...

Page 87: ...ING 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 pr...

Page 88: ...e precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep ing your feet on the footpegs 3 Steer slightly into the hill to maintain direction NOTE If the vehi...

Page 89: ...ff the engine Leaving the transmission in gear release the clutch lever and lock the parking brake 4 Dismount on the uphill side of the vehicle or on the left side if the vehicle is pointing straight...

Page 90: ...nward 8 With the front brakes still applied release the clutch lever and lock the parking brake Remount from the uphill side keeping body weight uphill 9 Pull in the clutch lever shift into neutral an...

Page 91: ...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 WARNING Excessive spee...

Page 92: ...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...

Page 93: ...ater 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After driving through w...

Page 94: ...t carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s imp...

Page 95: ...s 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 Alw...

Page 96: ...ure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle Follow the reverse operation pro...

Page 97: ...ain 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 N...

Page 98: ...to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of...

Page 99: ...ons 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...

Page 100: ...r Owner s Manual carefully Failure to perform the recommended procedures at the service intervals specified in your owner s manual will void warranty coverage and decrease the performance and reliabil...

Page 101: ...rts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Sev...

Page 102: ...will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease or grease conforming to NLGI No 2 WARNI...

Page 103: ...ours 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 lug nuts Frame fasteners Co...

Page 104: ...lendar Fuel Used in gallons liters Air box sediment tubes Pre ride Check each day before operating the vehicle Make adjustments as needed See the Pre Ride Check list 72 Headlamp Tail lamp brake lamp A...

Page 105: ...filter 15 Weekly Inspect clean replace as needed 122 X Oil and filter change 15 6 M 26 100 Perform initial oil change after first 3 hours of operation 110 X Oil screen drain plug 15 6 M 26 100 Clean...

Page 106: ...s See Page Hours Calendar Fuel Used in gallons liters Xz General lubrication 45 3 M 78 300 Lubricate all fittings pivots cables etc Carburetor float bowl 45 6 M 78 300 Drain bowl periodically and prio...

Page 107: ...6 M Inspect tighten fasteners grease after washing ATV driving in water Xz Front A Arms 2 45 6 M Inspect tighten fasteners grease also after washing ATV or driving in water Xz Rear Control Arm Bushin...

Page 108: ...ngs 60 12 M 104 400 Check spring length see dealer Cam chain tensioner 60 12 M 104 400 Check ratchet teeth for wear Coolant system 90 12 M 156 600 Pressure test system annually X Cooling system hoses...

Page 109: ...ction for wear Valve spring cap 90 156 600 Visual inspection for wear E Camshaft bearings 90 156 600 Replace E Valve springs 90 156 600 See your dealer or refer to the Dealer Service Manual perform me...

Page 110: ...pressure valve 90 156 600 Measure spring replace as needed Transmission 90 156 600 Check entire transmission bearings for wear replace as needed QE Ignition Timing 12 M Inspect adjust as needed Clutc...

Page 111: ...numbers of Polaris products NOTE Do not use Polaris PS 4 Performance Synthetic 10W 40 Oil Always use 2W 50 NOTE If the ATV is used year round check the oil level frequently A rising oil level could in...

Page 112: ...the sight glass If the engine is warm the oil level should be visible at the upper edge of the sight glass 1 Position the vehicle on a level surface 2 View the oil level through the sight glass on th...

Page 113: ...change both oil filters and clean the oil screens whenever changing oil NOTE Change the oil more frequently on vehicles subjected to severe use CAUTION If the ATV is left without oil in the system fo...

Page 114: ...3 Place a drain pan beneath the crankcase Remove the drain plug Allow the oil to drain completely 4 Clean the crankcase sealing surface and the drain plug with magnet thoroughly 5 Replace the sealing...

Page 115: ...112 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Hex Plug View from bottom of vehicle Front...

Page 116: ...page 2 Using a hammer tap lightly on the key a few times to loosen the seal Remove the plug 3 Remove the short oil screen Clean the screen components thoroughly and blow well with compressed air 4 Che...

Page 117: ...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 th...

Page 118: ...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 improperly installed oil screen will...

Page 119: ...sing circle clip snap ring pliers pull the oil filter inserts 2 out of the housing 4 Thoroughly clean the engine casing filter covers and sealing surfaces of the O rings Check the O rings If damaged i...

Page 120: ...g 4 Add 40 oz 1 2 liters of the recommended engine oil see page 108 Reinstall the fill plug 9 Start the engine Allow it to idle for at least one minute to fully distribute the new oil Stop the engine...

Page 121: ...ou completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of hig...

Page 122: ...e increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant...

Page 123: ...sure cap 2 Using a funnel slowly add coolant as necessary through the radiator filler neck 3 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to fu...

Page 124: ...sing a funnel slowly add the recommended coolant Fill the radiator to the bottom of the filler neck 3 Reinstall the pressure cap 4 Start the engine and allow it to idle for five minutes or until opera...

Page 125: ...ve the seat 2 Release the airbox cover clips and remove the cover 3 Loosen the filter clamp 4 Remove the air filter 5 Remove the inner and outer foam filter elements from the internal cage Clips Clamp...

Page 126: ...Wash the filters in soapy water then rinse and let dry 7 Apply a commercially available foam filter lubricant to the foam filters 8 Reinstall all components 9 Check the hoses for cracks deterioration...

Page 127: ...result in easier starting If idle speed is unsatisfactory use the following procedure to make adjustments 1 Position the vehicle on a level surface 2 Lock the parking brake Place the transmission in...

Page 128: ...aintenance 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 a suitable container under...

Page 129: ...ation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 305 m increase in elevation Although this...

Page 130: ...hat will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights f...

Page 131: ...e a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aime...

Page 132: ...counterclockwise to remove the bulb On the right headlamp turn the bulb housing clockwise to remove the bulb 3 Apply dielectric grease to the socket and install the new bulb Rotate firmly NOTE The bul...

Page 133: ...ts 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 headlamp by inserting t...

Page 134: ...e bracket and the edge of the headlight Tighten the mounting screws IMPORTANT Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freely 7 Install the adjusting screw leaving it lo...

Page 135: ...ment of the brake pedal 3 If the light does not operate properly grasp the switch body with a pliers or similar tool and hold it lightly but securely Using a wrench rotate the adjustment nut clockwise...

Page 136: ...arness connector from the cab The connector is located under the left fender 3 Remove the fuel tank cover screws 2 4 Remove the four side panel screws 3 5 Gently pull the cab upward to disengage it fr...

Page 137: ...134 Maintenance Side Panel Removal 1 Unlatch and remove the seat 2 Remove the front cab 3 Remove the two screws securing the side panel 4 Remove the side panel Side Panel Screws...

Page 138: ...enance 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 c...

Page 139: ...been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION Using non recommended spark plugs may result in serious engine damage and ma...

Page 140: ...ld not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is bl...

Page 141: ...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 tor...

Page 142: ...97 WARNING Failure to heed these warnings could result in serious injury or death Do not perform clean out immediately after the engine has been run as the exhaust system becomes very hot Serious bur...

Page 143: ...ve accumulated carbon 1 Remove the three screws 1 and remove the arrestor 2 from the end of the muffler 2 Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if compone...

Page 144: ...stor Clean Out 3 Inspect the screen for wear and damage Replace a worn or damaged screen 4 Remove and inspect the gasket 4 Replace a worn or damaged gasket 5 Reinstall the gasket and arrestor Torque s...

Page 145: ...water has entered the fuel tank likely if the water was deep or if the ATV over turned Tow or trailer the ATV to your dealer for immediate service CAUTION Do not start the engine after an ATV has been...

Page 146: ...See page 138 5 Intermittently and briefly touch the starter button in half second intervals to SLOWLY rotate the engine three or four times Water will eject from the spark plug hole continued on foll...

Page 147: ...Do not start the engine Transport the vehicle to your dealer for inspection and service If the oil level is unchanged from the pre ride inspection level replace the spark plug start the engine and mo...

Page 148: ...corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric...

Page 149: ...ut of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Battery Removal 1 Remove the front cab see page 133 2 Disconnect the...

Page 150: ...result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 1 Place the battery in the battery holder 2 Connect and tighten the red positive...

Page 151: ...echarged without removing it from the vehicle Use the remote charging ter minals under the right front cab NOTE The Polaris Battery Tender battery charger can be left connected during the storage peri...

Page 152: ...r s instructions for recharging When using a constant current charger use the guidelines on the following page for recharging WARNING An overheated battery could explode causing severe injury or death...

Page 153: ...rd amps specified on top of battery 100 12 8 13 0 volts None check at 3 months from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months...

Page 154: ...properly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the ow...

Page 155: ...mponent operations All service must be performed by your authorized Polaris dealer Wheel Removal 1 Stop the engine Place the transmission in gear Lock the parking brake 2 Loosen the wheel bolts slight...

Page 156: ...otation 3 Install the wheel bolts and finger tighten them 4 Lower the vehicle to the ground 5 Securely tighten the bolts to specification See page 152 WARNING Improperly installed wheels can adversely...

Page 157: ...ting 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 b...

Page 158: ...at may damage the boot 2 Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape 2 3 Wipe excess grease from the...

Page 159: ...stem any time the clutch lever feels unresponsive Always use the recommended fluid when bleeding the clutch system See page 55 1 Position the vehicle on a level surface Turn the handlebar until the ma...

Page 160: ...the master cylinder without producing bubbles NOTE Extract fluid from the master cylinder during the process to prevent overflowing 6 When finished remove the bleeder syringe 7 Reinstall the bleeder...

Page 161: ...8 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...

Page 162: ...ottle lever back and forth 4 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 5 WARNING Improper adjustment of throttle cable freeplay c...

Page 163: ...ep 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 which co...

Page 164: ...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 the disc 6 Inspect the rear...

Page 165: ...lebars in a straight ahead position Use tie straps to secure the handlebars to the rear grab bar so they can t move 3 Place stands in front of the vehicle perpendicular to the rear tires See illustrat...

Page 166: ...e string in front of the rear tires 1 and in front of the front tires 2 If the two measurements are not equal adjust the string position until the mea surements are equal 6 Measure the distance from t...

Page 167: ...in there should be 1 4 3 8 6 9 mm deflection Use the procedure on the following page if the chain needs adjustment NOTE The chain has a press on master link A chain tool must be used if it s necessary...

Page 168: ...ounting 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 b...

Page 169: ...right 3 Torque the two front bolts to 10 12 ft lbs 14 16 Nm then torque the two rear bolts NOTE A gap of up to 1 8 3 mm will remain at the rear bolts WARNING Improper adjustment of the handlebars or...

Page 170: ...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 Cam...

Page 171: ...lacing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the low...

Page 172: ...y to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 Subtract the step 8 measurement from the step 4 measurement The difference should be between 3...

Page 173: ...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 th...

Page 174: ...load 1 Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend 2 Turn the adjusting ring clockwise to increase preload 1 Turn the ring counter clockwis...

Page 175: ...e 3 Elevate the rear of the vehicle by plac ing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance...

Page 176: ...suspension 7 Turn the handlebars fully to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 9 Subtract the step 8 measurement from the step 4 measurem...

Page 177: ...ockwise 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...

Page 178: ...y be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the vehicle off the ground to allow the suspension to fully extend 2 Turn th...

Page 179: ...e shocks on the lower clevis Use a screwdriver to make adjustments To set the shock at the softest setting position 1 turn the screw counter clockwise until it stops From this position turn the screw...

Page 180: ...he 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 including insect r...

Page 181: ...e lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power...

Page 182: ...ecting the water stream at the following items Wheel bearings Electrical components and wiring Transmission seals Brakes Cab and body panels Labels and decals NOTE If warning and safety labels are dam...

Page 183: ...sh 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 Always use clean cloths an...

Page 184: ...ended 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 cre...

Page 185: ...Air Filter Air Box Inspect and clean or replace the air filter Clean the air box Drain the sediment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintenance Char...

Page 186: ...h and pro motes better starting after the storage period 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stop the...

Page 187: ...ure tire pressure is at specification 2 Be sure the storage area is well ventilated 3 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 4...

Page 188: ...top 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 A...

Page 189: ...200 w 3000 RPM Overall Height 45 in 114 cm Compression Ratio 11 1 Wheelbase 51 in 130 cm Starting System Electric Ground Clearance 11 5 in 29 cm Carburetor Keihin FCR MX 39mm Min Turning Radius 67 in...

Page 190: ...ft Type 5 Speed Manual Shift Tire Size Rear 20 x 10R9 Primary Ratio 2 516 Tire Pressure All 4 psi 27 6 KPa Gear Ratio 1st 2 500 Front Brake Hydraulic Disc Dual Bore Gear Ratio 2nd 1 941 Rear Brake Hyd...

Page 191: ...W 50 4 Cycle Oil gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 287...

Page 192: ...on 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 Clu...

Page 193: ...turned off Turn the fuel valve on Engine is cold Use choke to start a cold engine Interrupted fuel supply Turn the fuel valve off remove the fuel hose at the carburetor and place in a drain pan turn...

Page 194: ...times for 5 seconds each then restart If engine fails to start inspect clean and or replace spark plugs Low battery voltage Recharge battery to 12 8 VDC Ignition system or other mechanical failure See...

Page 195: ...Recharge battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octan...

Page 196: ...ncorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Exhaust leak Inspect system for leaks see your Polaris dealer Incorrectly inst...

Page 197: ...s dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Defective ignition system See your Polaris dealer Water pr...

Page 198: ...ogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Incorrect idle adjustment Adjust idle speed or see your Polaris dealer Clogged idle jet Di...

Page 199: ...on recommended fuel Replace with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke...

Page 200: ...e 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 Install a new hose Excessive...

Page 201: ...ted fuel supply Clean fuel system and carburetor Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure S...

Page 202: ...and or replace spark plugs Fouled or defective spark plug Inspect clean and or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set...

Page 203: ...ant Check levels and fill as needed check for leaks Insufficient air flow due to slow operation Operate at a faster speed to increase air flow Cooling system has not been bled Bleed the cooling system...

Page 204: ...el 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 dea...

Page 205: ...laris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will re...

Page 206: ...osion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that...

Page 207: ...OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Som...

Page 208: ...istance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms...

Page 209: ...have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s war ranty or service bu...

Page 210: ...vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the sell ing dealer s authorized location as proof of residence Upon residence verification t...

Page 211: ...ed outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Ve...

Page 212: ...rements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date This emission related...

Page 213: ...N TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above l...

Page 214: ...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 SERV...

Page 215: ...212 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 60 90...

Page 216: ...213 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 217: ...214 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 218: ...Carburetor Jetting 126 Chain Tension 164 165 Choke 68 Cleaning 177 179 Clothing 13 Clutch Fluid 55 Clutch Lever 54 Clutch System Bleeding 156 157 Compression Damping Rear 176 Consumer Product Safety 2...

Page 219: ...K Key Switch 51 K Turn 86 L Lights 52 53 127 132 Brake Light 132 Headlight Adjustment 128 Headlight Assembly 130 131 Headlights 53 Indicator Lights 52 M Main Key Switch 51 Maintenance Chart 97 107 Ma...

Page 220: ...Front 171 Spring Preload Rear 175 Starting the Engine 75 77 Steering Inspection 167 Storage 181 184 Suspension Front 168 171 Rear 172 176 Suspension Set Up 168 173 Switches Engine Stop Switch 51 Main...

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Polaris 2007 Outlaw 525, Owner'S Manual

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