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Polaris 2009 Outlaw 450 MXR, Owner'S Manual

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Polaris 2009 Outlaw 450 MXR Owner'S Manual Download Page 142

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.

6. When finished, remove the bleeder syringe. 
7. Reinstall the bleeder screw.
8. Add or remove fluid as needed to maintain the level 4mm below the top edge of the mas-

ter cylinder reservoir.

9. Reinstall the cover, boot and screws securely. 

Summary of Contents for 2009 Outlaw 450 MXR

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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: ...ality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are int...

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

Page 8: ...tents Introduction 6 Safety 10 Features and Controls 38 Operation 58 Emission Control Systems 85 Maintenance 87 Specifications 168 Polaris Products 172 Troubleshooting 174 Warranty 186 Maintenance Log...

Page 9: ...tial personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not...

Page 10: ...ety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a ne...

Page 11: ...ers 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 w...

Page 12: ..._________________________ Frame Vehicle Identification Number 1 __________________________________________________________ Engine Serial Number 2 ______________________________________________________...

Page 13: ...aris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm You were also provided with printed materi als that explain safe operating pr...

Page 14: ...the recommended maintenance program outlined in your owner s manual This program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals FOR M...

Page 15: ...equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if...

Page 16: ...ts 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...

Page 17: ...sonal 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 p...

Page 18: ...ions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road use o...

Page 19: ...ators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner...

Page 20: ...d 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 change clothing Exposure to...

Page 21: ...ntenance procedures and schedules described in the owner s manual Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of a...

Page 22: ...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 adversely affect op...

Page 23: ...void operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public stre...

Page 24: ...nditions and your experience Physical Control of the ATV Removing a hand from the handlebars or feet from the footpegs during operation can reduce your ability to control the vehicle or cause loss of...

Page 25: ...for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stu...

Page 26: ...n 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 Never operate...

Page 27: ...required when braking while traveling downhill See page 78 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain...

Page 28: ...urn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 74 Never attempt t...

Page 29: ...lever When fully stopped apply the foot brake as well and then lock the parking brake If the ATV begins rolling downhill Keep weight uphill Never apply engine power Never apply the rear brake while ro...

Page 30: ...y rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the...

Page 31: ...ly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 82 Before shifting in...

Page 32: ...to approved instructions See your authorized Polaris ATV dealer for more information Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operat...

Page 33: ...If it s unavoidable to enter water that exceeds the height of the footpegs Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudd...

Page 34: ...duced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly Improper Cargo Loading Overloading the ATV or carrying towing cargo may cause chang...

Page 35: ...Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes thr...

Page 36: ...hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the...

Page 37: ...ual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your Polaris...

Page 38: ...aining or instruction at speeds too fast for your skills or the condi tions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and incre...

Page 39: ...To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of contr...

Page 40: ...g in SEVERE INJURY or DEATH 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pr...

Page 41: ...38 Features and Controls Start Button Engine Stop Switch Main Key Switch...

Page 42: ...he start button promptly when the engine starts If the starter fails to engage replace the blown fuse or see your Polaris dealer Engine Stop Switch Move the stop switch either left or right to the OFF...

Page 43: ...dicator window will alert you to the follow ing conditions Hot engine Reverse gear is selected Neutral gear is selected If indicator lights fail to operate check connections See your Polaris dealer fo...

Page 44: ...s 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 t...

Page 45: ...adjusting knob counterclockwise to move the lever closer to the handle bar Turn the adjusting knob clockwise to move the lever away from the handlebar The adjustment range is limited Never apply exces...

Page 46: ...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 172 for the part numbers of Polaris products 1 Position the vehicle on a...

Page 47: ...throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during o...

Page 48: ...rting the engine Do not squeeze the throttle lever when the engine is stopped Engine speed returns to idle when the lever is released See page 141 for throttle adjustment procedures This ATV is equipp...

Page 49: ...y for the foot brake system The reservoir is located under the seat Maintain the fluid level between the minimum and maximum marks WARNING Aggressively applying the foot brake when backing down a hill...

Page 50: ...r fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contac...

Page 51: ...Do not overfill Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake...

Page 52: ...ATV on a level surface Position the handlebars so the master cylinder is level 2 View the fluid level through the indicator window on the side of the master cylinder 3 Maintain the fluid level at or...

Page 53: ...old 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 the brake lever The lock will automatically disengage WARNING...

Page 54: ...Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend...

Page 55: ...ar in the shifting sequence The pedal automatically returns to a horizontal position when released To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal...

Page 56: ...brake lever 6 Gradually squeeze the throttle lever while slowly releasing the clutch lever 7 As engine speed RPM increases in first gear simultaneously release the throttle disengage the clutch and s...

Page 57: ...ionally The switch must be manually unlocked before shifting into reverse gear The lock will automatically re engage when the transmission is shifted out of reverse gear 1 Place the transmission in fi...

Page 58: ...creases disengage the clutch and shift to a lower gear Be sure engine speed has sufficiently decreased before downshifting WARNING Improper use of the brakes or shifting when the engine speed is too h...

Page 59: ...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 60: ...porting Turn the fuel valve off whenever the vehicle is stored or parked ON For normal operation RES For reserve supply if main supply is exhausted There s about a 5 to 8 mile 8 to 13 km range on rese...

Page 61: ...me it takes to use 5 6 gallons 20 liters of fuel No single action on your part is as impor tant as following the procedures for a proper break in Careful treatment of a new engine and transmission wil...

Page 62: ...area that allows room to familiarize yourself with vehicle operation and handling 5 Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not allow...

Page 63: ...condition Pre Ride Checklist Page Brake systems lever travel Ensure proper operation 46 51 142 143 Brake fluid Ensure proper level 48 Clutch lever Check for proper operation and adjustment 42 Clutch...

Page 64: ...ne stop switch Ensure proper operation 39 Air filter Inspect clean replace as needed 112 Air box sediment tubes Drain deposits when visible Headlamp Verify operation apply Polaris dielectric grease to...

Page 65: ...le off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 6 Use caution and drive at reduced speeds in conditions of reduced visibi...

Page 66: ...e or while operating an ATV 10 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 11 Never operate a damaged ATV After any overturn or accident have...

Page 67: ...e Find out where the desig nated riding areas are by contacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusi...

Page 68: ...w 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...

Page 69: ...hrottle lever while starting the engine Do not depress the throttle lever when the engine is stopped NOTICE Operating the ATV immediately after starting could cause engine damage Allow the engine to w...

Page 70: ...tart the engine Activate the starter for a maximum of five seconds Release the start button immediately when the engine starts NOTICE Excessive engagement may result in starter damage 8 If the engine...

Page 71: ...and allow it to warm up 4 Shift the transmission into gear See page 52 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your...

Page 72: ...ion of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balance of traction between the rear wheels allowing the t...

Page 73: ...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...

Page 74: ...riving 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 dir...

Page 75: ...mproper 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 terrain carefull...

Page 76: ...V to flip over backwards 8 Never back down a hill WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover 9 Never go over the top of any hill at high speed An obst...

Page 77: ...the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep i...

Page 78: ...the front and rear brakes 3 When completely stopped shut off the engine Leaving the transmission in gear release the clutch lever and lock the parking brake 4 Dismount on the uphill side of the vehic...

Page 79: ...ver Use the brakes to slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly down ward 8 With the front brakes still applied release the clutch lever and...

Page 80: ...tart 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...

Page 81: ...hill 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 5 Shift to the lowest gear possible while m...

Page 82: ...ing 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 down...

Page 83: ...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 bot...

Page 84: ...ting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying proced...

Page 85: ...s 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...

Page 86: ...Use just enough throttle to maintain a desired speed 8 Always look left right and behind the ATV before backing NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to buil...

Page 87: ...ting 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 use extra caution when operating on unfami...

Page 88: ...SDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lan...

Page 89: ...cations to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer T...

Page 90: ...forfeited warranty coverage as well as decreased performance and reliability of the vehicle If you re unable to perform the required service and adjustment procedures have a qualified dealer perform t...

Page 91: ...verage 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 us...

Page 92: ...have an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often under severe use E Emission related service Failure to conduct this maintenance wi...

Page 93: ...urs 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 lug nuts Frame fasteners Coo...

Page 94: ...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 60 Headlamp Tail lamp brake lamp A...

Page 95: ...ct clean replace as needed 112 X Oil and filter change 15 6 M 26 100 Perform initial oil change after first 3 hours of operation 100 X Oil screen drain plug 15 6 M 26 100 Clean screen and plug magnet...

Page 96: ...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 97: ...emarks Hours Calendar Fuel Used in gallons liters Xz Upper steering post 1 45 6 M Inspect tighten fasteners grease after washing ATV driving in water Xz Front A Arms 2 45 6 M Inspect tighten fasteners...

Page 98: ...gs 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 9...

Page 99: ...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 100: ...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 Clutch...

Page 101: ...rmance Synthetic 10W 40 Oil Always use 2W 50 See page 172 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the re...

Page 102: ...ght 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 vehicle on a level surface 2 View the oil level through the sight glass...

Page 103: ...ration Always change both oil filters and clean the oil screens whenever changing oil Before beginning the oil change procedure read through the entire procedure Be prepared to complete the procedure...

Page 104: ...gine 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 Do not allow hot oil to contact skin 4 Clean the crankcas...

Page 105: ...102 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Short Oil Screen Plug View from bottom of vehicle Front O Rings...

Page 106: ...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 4 Reins...

Page 107: ...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 108: ...of the opposite engine casing wall Push the oil screen into the casing as far as possible Remove the tool NOTICE An improperly installed oil screen will function poorly and result in increased engine...

Page 109: ...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 110: ...ug 4 Add 40 oz 1 2 liters of the recommended engine oil see page 98 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 111: ...hat you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture o...

Page 112: ...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 is...

Page 113: ...steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Remove the pressure cap 2 Using a funnel slowly...

Page 114: ...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 115: ...e placement of the rubber ring for rein stallation 5 Wash the filter in soapy water then rinse and let dry 6 Apply a commercially available foam filter lubricant to the foam filter 7 Reinstall the rub...

Page 116: ...l result in easier starting If idle speed is unsatisfactory make adjustments as outlined on page 113 Idle Speed 1 Position the vehicle on a level surface Lock the parking brake Place the transmission...

Page 117: ...aintenance 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 a suitable container under...

Page 118: ...peration 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 th...

Page 119: ...e 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 t...

Page 120: ...ll 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...

Page 121: ...denatured alcohol 1 Remove the wire harness connector from the back of the headlight 2 Grasp the bulb housing and turn it counterclockwise to remove the bulb CAUTION Hot components can cause burns to...

Page 122: ...e adjuster screw 4 Remove the headlamp 5 Install the new headlamp placing it in the slots on the frame tabs Secure the headlamp with the retaining brackets 6 Install the adjuster screw leaving it loos...

Page 123: ...ver 3 Remove the eight side panel screws four on each side 4 Remove the fuel cap 5 Gently pull the side panel cab assembly upward and rearward 6 Unplug the key switch and the indicator panel before re...

Page 124: ...e 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 th...

Page 125: ...firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color 1 Access the spark plug at...

Page 126: ...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 blac...

Page 127: ...tremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protect...

Page 128: ...screw and remove the arrestor from the end of the muffler 2 Use a non synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If neces sary blow debris from the...

Page 129: ...estarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined below This proce dure will allow short term operation only to drive the ATV to a tra...

Page 130: ...ARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Wear protective eyewear and stand clear of the spark plug while performing the follow...

Page 131: ...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 132: ...d battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery Keep the battery terminals and...

Page 133: ...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 rear cab see page 120 2 Disconnect the h...

Page 134: ...sult 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 ca...

Page 135: ...ated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Th...

Page 136: ...pre determined point If the battery fails to recharge during vehicle operation check voltage regulator connections See your Polaris dealer for inspection of the voltage regulator and generator When us...

Page 137: ...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 3...

Page 138: ...an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type w...

Page 139: ...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 140: ...ith 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 vehicle 3 Install the wheel bolts a...

Page 141: ...stem any time the clutch lever feels unresponsive Always use the recommended fluid when bleeding the clutch system See page 43 1 Position the vehicle on a level surface Turn the handlebar until the ma...

Page 142: ...in the master cylinder without producing bubbles Extract fluid from the master cylinder during the process to prevent overflowing 6 When finished remove the bleeder syringe 7 Reinstall the bleeder scr...

Page 143: ...0 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...

Page 144: ...who perform this procedure must follow the adjustment procedures exactly 1 Locate the throttle cable at the handlebar 2 Slide the boots off the inline cable adjuster sleeve and loosen the locking nut...

Page 145: ...fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury...

Page 146: ...m 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 re...

Page 147: ...injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position...

Page 148: ...you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be between 0 and 1 16 0 1 5...

Page 149: ...h the rear drive chain too loose or too tight Severe damage to the transmission and drive components can result Chain tension must be inspected with the swing arm in the position shown in the illustra...

Page 150: ...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 intersecting the swing arm pivot This establishes the tightest chain p...

Page 151: ...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...

Page 152: ...149 Maintenance Chain Tension Adjustment Step 1 Step 2 Proper splicelink clip opening position...

Page 153: ...actly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Loosen the four handlebar bolts 2 Adjust the handlebar to the desired height Be sure the handlebars d...

Page 154: ...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 155: ...d position Rear Shock Standard and Limited Edition Front Shock Limited Edition Setting Compression Damping Rebound Damping Softest 20 clicks from closed 24 clicks from closed Factory 10 clicks from cl...

Page 156: ...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 adjust...

Page 157: ...the left 1 to increase preload for a stiffer ride Turn the adjusting ring to the right 2 to decrease preload for a softer ride See Suspension Set tings on page 152 WARNING Uneven adjustment may cause...

Page 158: ...load 1 Raise and safely support the rear 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 t...

Page 159: ...ng 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 shock mount 2 Turn the clicke...

Page 160: ...tting 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 fender 1 Turn the clicker cloc...

Page 161: ...ld soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle Washing the Vehicle The best and safest way...

Page 162: ...aners 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 Ol...

Page 163: ...ing and safety labels are damaged contact your Polaris dealer for free replacement Avoid direct ing the water stream at the following items Wheel bearings Electrical components and wiring Transmission...

Page 164: ...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 165: ...rb 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 Batt...

Page 166: ...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 167: ...and promotes 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 eng...

Page 168: ...e sure tire pressure is at specification 2 Be sure the storage area is well ventilated 3 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the groun...

Page 169: ...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...

Page 170: ...167 Maintenance Transporting the ATV...

Page 171: ...all Height 45 in 114 cm Compression Ratio 11 1 Wheelbase 50 5 in 128 cm Starting System Electric Ground Clearance 5 in 13 cm Carburetor Keihin FCR MX 39mm Min Turning Radius 67 in 170 cm Ignition Syst...

Page 172: ...ar Ratio 2nd 1 941 Rear Brake Hydraulic Disc Gear Ratio 3rd 1 579 Parking Brake Hydraulic lock front wheel Gear Ratio 4th 1 333 Headlight Dual Beam 55w 60w Gear Ratio 5th 1 130 Taillight LED Gear Rati...

Page 173: ...all Height 45 in 114 cm Compression Ratio 11 1 Wheelbase 50 5 in 128 cm Starting System Electric Ground Clearance 5 in 13 cm Carburetor Keihin FCR MX 39mm Min Turning Radius 67 in 170 cm Ignition Syst...

Page 174: ...Ratio 2nd 1 941 Rear Brake Hydraulic Disc Gear Ratio 3rd 1 579 Parking Brake Hydraulic lock front wheel Gear Ratio 4th 1 333 Headlights Dual Beam 55w 60w Gear Ratio 5th 1 130 Taillight LED Gear Ratio...

Page 175: ...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 176: ...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 28763...

Page 177: ...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 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...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 185: ...uel system and carburetor Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer...

Page 186: ...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 187: ...eded check for leaks Insufficient air flow due to slow operation Operate at a faster speed to increase air flow Excessive oil in system Check oil level maintain at recommended level Cooling system has...

Page 188: ...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 189: ...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 190: ...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 191: ...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 192: ...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 193: ...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 194: ...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 195: ...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 196: ...r this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date after 5000 km 3100 miles or after 500 hours of operation which...

Page 197: ...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 198: ...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 199: ...196 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 60 90...

Page 200: ...197 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 201: ...198 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 202: ...n 146 147 Cleaning 158 160 Clothing 14 Clutch Fluid 43 Clutch Lever 42 Clutch System Bleeding 138 139 Compression Damping 153 Compression Damping Rear 157 Consumer Product Safety 11 Coolant Level Radi...

Page 203: ...6 J Jetting 115 Jetting Specifications Outlaw 450 MXR 169 Outlaw 525 S 171 K Key Switch 39 K Turn 75 L Lights 40 41 116 119 Headlight Adjustment 116 117 Headlight Assembly 119 Headlights 41 Indicator...

Page 204: ...21 Exposure to Exhaust 17 Failure to Inspect 18 Frozen Bodies of Water 32 Handling Gasoline 17 Hot Exhaust Systems 33 Improper Cargo Loading 31 Improper Hill Climbing 23 Improper Tire Maintenance 28...

Page 205: ...h 39 Reverse Lock Out Switch 54 Start Button 39 T Throttle Cable Freeplay 141 Throttle Lever 44 45 Throttle Lever Freeplay 140 Tires Installation 137 Removal 136 Tread Depth 135 Wheel Hub Tightening 1...

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