Polaris 2009 Outlaw 525 IRS Owner'S Manual Download

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129

Maintenance

Battery

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious

injury or death. When removing the battery, always disconnect the negative (black) cable first. When

reinstalling the battery, always connect the negative (black) cable last.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at

the factory.

Never

pry the sealing strip off or add any other fluid to this battery.

Keep the battery terminals and connections free of corrosion. If cleaning is necessary,

remove the 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 grease or petroleum jelly.

WARNING

Summary of Contents for 2009 Outlaw 525 IRS

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Page 3: ...er 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 California to cause cancer birth defects or other reproductive harm ...

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

Page 5: ...d 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 are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is ex...

Page 6: ...sing 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: ...er 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 Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during a...

Page 8: ...ntents Introduction 6 Safety 10 Features and Controls 38 Operation 58 Emission Control Systems 86 Maintenance 85 Specifications 168 Polaris Products 170 Troubleshooting 172 Warranty 184 Maintenance Log 193 Index 197 ...

Page 9: ...ntial 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 avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a...

Page 10: ...fety 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 new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in t...

Page 11: ...res at the service intervals specified in your owner s manual will void war ranty coverage and decrease the performance and reliability of your vehicle Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your ke...

Page 12: ...______________________________ Frame Vehicle Identification Number 1 ______________________________________________________ Engine Serial Number 2 __________________________________________________________________ Key Number on the key __________________________________________________________________ 2 1 ...

Page 13: ...laris 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 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 Express at 800 887 2887 or by visiting ...

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 MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 ...

Page 15: ...l 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 any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may chan...

Page 16: ...ets 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 The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing num ber of the country which has granted approval The approval number and serial number will also be displa...

Page 17: ...rsonal 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 protection Boots The best footwear is a pair of strong over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with knee pads and a je...

Page 18: ...tions Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age This category S Sport ATV is a high performance vehicle intended for off road use only for sport type recreation and for competitive use by operators with advanced skills and substantial experience Even though a child may be within the recommended age group for operating some ATVs ...

Page 19: ...rators 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 s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org Never permit a guest to operate the ATV unless the guest has read ...

Page 20: ...ed 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 Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area The engine exhaust from this product ...

Page 21: ...intenance 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 an accident Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident Always wear an approved helmet that fits properly...

Page 22: ...e 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 operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV ...

Page 23: ...Avoid 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 streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to opera...

Page 24: ...onditions 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 balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could also contact the rear wheels Never remove your hands from the handlebars while operating and alw...

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 Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving ...

Page 26: ...rn 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 on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 25 ...

Page 27: ...s required when braking while traveling downhill See page 75 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side ...

Page 28: ...turn 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 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 76 ...

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 rolling backwards Apply the front brake slowly When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphil...

Page 30: ...ly 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 skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain ...

Page 31: ...rly 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 into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven t...

Page 32: ...g 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 operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined ...

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 sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction ...

Page 34: ...educed 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 changes in handling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not hav...

Page 35: ...V 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 throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this veh...

Page 36: ...h 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 keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use ...

Page 37: ...nual 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 dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part num ber is printed on the label Age 16 Warning General Warning Discretionary Sport ATV Warnin...

Page 38: ...raining 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 increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seri ously affect handling and cont...

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 control avoid sudden braking or sharp turns This ATV may exceed the performance of other ATVs you may have ridden in the past This category S Sport ATV is a high performance vehicle for off road use only ...

Page 40: ...ng 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 pressure Front 4 0 psi 27 6 kPa Rear 4 0 psi 27 6 kPa Maximum Weight Capacity 215 lbs 98 kg 7175445 Tire Pressure Warning No Passenger Warning ...

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

Page 42: ...the 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 position to stop the engine quickly The engine will not start or run when the switch is off Both the main switch and the engine stop switch will shut off all electrical power to the vehicle includin...

Page 43: ...ndicator 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 for inspection of the capacitor and voltage regulator Reverse Neutral Hot Engine ...

Page 44: ...ts Use the headlight switch to turn the lights on and off and to switch the lights from high beam to low beam The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights Headlight Switch ...

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 excessive force to the knob Always turn the knob manually Always check the lever for smooth operation before riding If the lever does not operate smoothly check the fluid level at the master cylinder See ...

Page 46: ...ends the use of KTM Hydraulic Clutch Oil Do not use brake fluid Do not mix clutch fluid with any other hydraulic fluids See page 170 for the part numbers of Polaris products 1 Position the vehicle on a level surface 2 Turn the handlebar until the master cylinder is in a horizontal position 3 Remove the two cover screws the cover and the rubber boot 4 Add the recommended fluid as needed 5 Reinstall...

Page 47: ...e 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 operation Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or repl...

Page 48: ...rot tle lever while starting 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 143 for throttle adjustment procedures This ATV is equipped with an Electronic Throttle Con trol ETC which is designed to reduce the risk of a fro zen or stuck throttle If the throttle cable should stick in an open position when the o...

Page 49: ...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 119 WARNING Aggressively applying the foot brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill Use caution when applying the foot brake Do not aggressively...

Page 50: ...er 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 Contact your dealer for proper diagnosis and repairs WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feel...

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 fluid to drop which can lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion WARNING...

Page 52: ...e 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 slightly above the mark near the center of the sight glass Do not overfill Foot Brake Fluid Level 1 Position the ATV on a level surface 2 Remove the seat and view the fluid level in the reservoir Mai...

Page 53: ...ld 3 Push the parking brake lock inward to engage the lock Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The lock will automati cally disengage WARNING Operating the ATV while the parking brake is engaged could result in an accident Always check to be sure the parking brake is disengaged before operating ...

Page 54: ...nt 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 alone if the ATV is parked on a hill Always block the wheels to prevent rolling Place the transmission in first gear before locking the parking brake ...

Page 55: ...next gear 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 one full stroke To downshift place your foot on the gear shift pedal and depress the pedal one full stroke See page 53 To shift into reverse see page 54 Upshift Downshift ...

Page 56: ... gear 5 Release the 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 shift to second gear by raising the gear shift pedal one full stroke Repeat this proce dure to progressively upshift to addi tional gears WARNING Shifting without releasing the throt...

Page 57: ...tionally 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 first gear See page 52 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into reverse gear Lock Out Lever ...

Page 58: ... disengage the clutch and shift to a lower gear 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 speed is too high can cause the tires to lose traction or stop rotating which could result in loss of control NOTICE Shifting when engine speed is too high can also cause engine and drive train damage ...

Page 59: ...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 fuel Fuel Filters The fuel pick ups have internal fuel filters Do not attempt to clean the fuel filters See your Polaris dealer for service if you suspect the fuel filters are plugged Choke Knob ...

Page 60: ...sporting 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 reserve gas Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling Fuel Valve ...

Page 61: ...ime 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 will result in more efficient performance and longer life for both Do not allow engine speed to exceed 7000 RPM during the break in period Follow the break in period with an additional 12 hours of cauti...

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 engine speed to exceed 7000 RPM dur ing the first three hours of use 6 Vary throttle positions Do not operate at sustained idle 7 Perform regular checks on fluid levels controls and areas outlined o...

Page 63: ...g condition Pre Ride Checklist Page Brake systems lever travel Ensure proper operation 46 51 144 145 Brake fluid Ensure proper level 48 Clutch lever Check for proper operation and adjustment 42 Clutch fluid Ensure proper level 43 Suspension front and rear Inspect lubricate if necessary 92 Steering Check for free operation loose components Frame nuts bolts fasteners Inspect ensure tightness Fuel an...

Page 64: ...ter Inspect clean replace as needed 110 Air box sediment tubes Drain deposits when visible Headlamp Check operation apply Polaris dielectric grease to the socket when the lamp is replaced 117 Brake light tail lamp Check operation adjust brake light switch 119 Riding gear Wear helmet goggles protective clothing 13 A arm ball joints Check freeplay If the tire moves excessively do not operate See you...

Page 65: ...cle 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 visibility such as fog rain and darkness Clean head lights frequently and replace burned out headlamps promptly 7 Never exceed the maximum weight capacity of the vehicle When determin ing the weight you ar...

Page 66: ...re 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 a quali fied service dealer inspect the entire machine for possible damage 12 Never operate the ATV on a frozen body of water 13 Do not touch hot exhaust system com ponents Always keep combustible ma...

Page 67: ...de 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 enthusiast you repre sent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated tra...

Page 68: ...ow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely ...

Page 69: ...le 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 warm up for several minutes before operating 1 Shift the transmission to neutral 2 Lock the parking brake Turn the fuel valve on 3 Sit on the vehicle Disengage the clutch 4 If the engine is cold pull the ch...

Page 70: ...start 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 does not start wait five seconds after releasing the start button then acti vate the starter for another five seconds Repeat until the engine starts If the engine does not start review the engine tro...

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 right thumb while slowly releasing the clutch lever to begin driving 8 Drive slowly Practice maneuvering and using the throttle clutch and brakes on level surfaces ...

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 turn to be made smoothly The same leaning technique should be used for turn ing in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can...

Page 73: ...el 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 skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward ...

Page 74: ...Driving on Slippery Surfaces 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Sideways skid Turn in direction of skid ...

Page 75: ...Improper procedure could cause loss of control or overturn Whenever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 25 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slip pery or loose surfaces 25 Maximum ...

Page 76: ...TV 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 obstacle a sharp drop or another vehicle or person could be on the other side of the hill 10 Remain alert and be prepared to take emergency action This may include quick dis mounting of the vehicle ...

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 ing your feet on the footpegs 3 If the vehicle begins to slide or tip quickly turn the front wheel down hill if possible or dismount on the uphill side immediately ...

Page 78: ...t uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when trav eling downhill can cause loss of control 5 Shift to the lowest gear possible while maintaining a safe speed 6 Do not apply the brakes abruptly when driving downhill Apply the foot brake slightly to aid in slowing ...

Page 79: ...y 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 vehicle or on the left side if the vehicle is pointing straight uphill 5 Staying uphill of the ATV turn the handlebars full left 6 Reach across the handlebar and apply the front brakes to unlock the parki...

Page 80: ... 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 and restart the engine 10 Release the parking brake and slowly release the clutch lever allowing the ATV to proceed slowly Stay in first gear using the brakes for additional speed control if necessary until more level ground is reached 11 Follow...

Page 81: ...n a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Turn the fuel valve off ...

Page 82: ...ating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees ...

Page 83: ...e height of the footpegs Follow these procedures 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 both banks have gradual inclines 3 Avoid operating through deep or fast flowing water Maximum Depth ...

Page 84: ...rting 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 procedures outlined on page 126 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out...

Page 85: ...kes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly while back ing Do not operate at full throttle Use just enough throttle to maintain a desired speed 7 Always look left right and behind the ATV before backing NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine da...

Page 86: ...he 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 off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This en...

Page 87: ... 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 The compliance label is located on a frame tube to the left side of the frame behind the radi ator Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies wi...

Page 88: ...s outlined in the Periodic Main tenance Chart will result in 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 these operations Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use ge...

Page 89: ...average riding conditions Vehicles sub jected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation ...

Page 90: ...s 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 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 WARNIN...

Page 91: ...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 60 Tires Wheels lug nuts Frame fasteners Coolant Fuel Engine oil Transmission oil Throttle Clutch system clutch fluid Lights Engine stop switch Steering ...

Page 92: ...alendar 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 arm ball joint Rear shaft assembly Boots Post ride Burp boots if bulging ballooned 139 Oil and filter change 3 Break in 5 20 Change the oil and filters 98 Oil screen drain plug Clean screen and plug...

Page 93: ...Air filter 15 Weekly Inspect clean replace as needed 110 X Oil and filter change 15 6 M 26 100 Perform initial oil change after first 3 hours of operation 98 X Oil screen drain plug 15 6 M 26 100 Clean screen and plug magnet 100 Idle speed 15 6 M 26 100 Check adjust as needed 112 Engine mounting bolts 15 6 M 26 100 Check torque Shift lever bolt 15 6 M 26 100 Check torque E Valve clearance 15 6 M 2...

Page 94: ...ks 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 prior to storage 113 QE Throttle cable ETC switch 45 6 M 78 300 Inspect adjust replace as needed 143 X Drive chain s 45 6 M 78 300 Inspect daily adjust lubricate if needed 149 XQ Brake pad replacement 45...

Page 95: ...pper 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 grease also after washing ATV or driving in water Xz Stabilizer Bar 3 45 6 M Grease Xz Rear Control Arm Needle Bearings 4 90 12 M Disassemble clean inspect bearings seals grease reassemble 2 2 4 3 4 1 ...

Page 96: ...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 90 12 M 156 600 Inspect Radiator 90 12 M 156 600 Inspect clean external surface change coolant every 2 years QE Fuel system 90 12 M 156 600 Check for leaks at tank cap lines fuel valve filter carburet...

Page 97: ...ection 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 measurements replace as needed E Valve seats guides 90 156 600 E Rocker arm rollers 90 156 600 E Timing chain 90 156 600 Measure elongation replace as needed Cam chain tensioner 90 156 600 Check ratche...

Page 98: ... 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 fluid 90 12 M Bleed as needed change yearly 140 QE Jet needle needle jet 180 24 M Replace Q Brake fluid 180 24 M Replace Spark arrestor 300 36 M Clean out 124 Q Front rear wheel bearings 300 36 M In...

Page 99: ...ormance Synthetic 10W 40 Oil Always use 2W 50 See page 170 for the part numbers of Polaris products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or exces...

Page 100: ... visible at the center of the sight glass A high oil level can cause engine overheating which could result in engine damage Always maintain the oil level as recommended 1 Position the vehicle on a level surface 2 View the oil level through the sight glass on the right side of the vehicle 3 Remove the fill plug and add the recom mended oil as needed 4 Reinstall the fill plug Sight Glass Fill Plug W...

Page 101: ...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 entirely Do not allow the vehicle to be without oil and filter over night Always replace the oil and filters within a few hours of draining the oil NOTICE If the ATV is left without oil in the system ...

Page 102: ...idle for two to three minutes Stop the engine 4 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 5 Clean the crankcase sealing surface and the drain plug with magnet thoroughly 6 Replace the sealing ring Reinstall the drain plug Torque to 15 ft lbs 20 Nm Drain Plug ...

Page 103: ...100 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Short Oil Screen Plug View from bottom of vehicle Front O Rings ...

Page 104: ...e engine See illustration on preceding page 2 Remove the short oil screen from the plug Clean the screen components thoroughly and blow well with compressed air 3 Check the O rings If damaged install new O rings 4 Reinstall the screen to the plug 5 Lubricate the threads and reinstall the plug Torque to 7 5 ft lbs 10 Nm ...

Page 105: ...g 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 the long oil screen on a pin type key or similar tool of about 12 inches 300 mm in length Plug ...

Page 106: ... 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 wear Install the screen securely at the angle shown in the illustration 6 Reinstall the plug Torque to 11 ft lbs 15 Nm ...

Page 107: ...Using 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 install new O rings 5 Fill each oil filter with oil Install the long filter at the front of the filter box Install the short filter at the rear of the box 1 2 ...

Page 108: ...plug 4 Add 1 7 qts 1 6 l of the recommended engine oil see page 96 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 10 Check for leaks at all threaded connections and at the oil filter covers 11 View the oil level in the sight glass Add oil as needed to maintain the level as recommended see page 97 3 4 ...

Page 109: ...that 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 of high quality aluminum compatible anti freeze coolant and distilled water Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Polaris Premium 60 4...

Page 110: ... 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 drawn back up from the tank past the pressure cap and into the radiator Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and ma...

Page 111: ...g 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 add coolant as necessary through the radiator filler neck 3 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer f...

Page 112: ...Using 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 operating temperature is reached 5 Stop the engine 6 After the engine has cooled add additional coolant to refill the radiator to the bottom of the filler neck 7 Operate the vehicle for 20 minutes allow t...

Page 113: ...e the retaining spring 5 Carefully remove the retaining spring from the filter 6 Remove the inner and outer foam filter elements from the internal cage 7 Separate the two filters Wash the filters in soapy water then rinse and let dry 8 Apply a commercially available foam filter lubricant to the foam filters 9 Reinstall all components 10 Check the hoses for cracks deterioration abrasion or leaks Re...

Page 114: ...111 Maintenance Air Filter Systems Step 3 Step 5 Step 4 Step 7 Step 6 ...

Page 115: ...ill 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 neutral 3 Start the engine and allow it to idle for five min utes or until operating temperature is reached 4 Turn the idle adjusting wheel 1 until idle speed reaches 1500 1600 RPM 5 If idle speed ...

Page 116: ...Maintenance Chart beginning on page 85 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 the carburetor to collect drained fluid 3 Remove the hex plug 1 Allow fluids to drain 4 Reinstall the hex plug securely 1 ...

Page 117: ...operation 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 power cannot be regained changes to the carburetor and drive system can be made to allow more efficient operation Contact your dealer for altitude adjustments Your dealer has the training and spec...

Page 118: ...he 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 the headlight switch to high beam 2 5 cm Lamp Center Height 25 ft 7 6 m General Representation ...

Page 119: ...t intense part of the headlight beam should be aimed 2 5 cm below the mark placed on the wall Include rider weight on the seat when measuring 5 Loosen the pivot screw and adjust the beam to the desired position 6 Tighten the screw and torque to 27 in lbs 3 Nm Pivot Screw ...

Page 120: ...h 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 skin Allow lamps to cool before servicing 3 Apply dielectric grease to the socket and install the new bulb Rotate firmly The bulb must be positioned so the harness installs into the lamp at outer si...

Page 121: ...he 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 loose so the headlight can be adjusted 7 Connect the wire harness to the headlamp Reinstall the front cover 8 Adjust the lamp as needed see page 115 then tighten the adjuster screw ...

Page 122: ...ement 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 to increase tension on the spring TIP Rotate the adjusting nut counter clockwise to decrease tension on the spring if the brake light comes on when there is no pressure on the brake pedal 4 Recheck ...

Page 123: ...over 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 removing the cab 7 To remove a side panel from the cab remove the corre sponding push pin and slide the panel forward to disen gage the locking tabs Side Panel Screws Front Cover Screws ...

Page 124: ...move the seat 2 Remove the two lower bolts 1 on the rear fenders of the cab 3 Remove the two bolts and grommets 2 on the top of the cab 4 Remove the two bolts 3 at the rear cab to front cab joint 5 Unplug the taillight connector 6 Remove the cab 1 3 2 ...

Page 125: ...g 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 the right side of the engine 2 Using the spark plug socket and a wrench rotate counter clockwise to remove the spark plug CAUTION A hot exhaust system and engine can cause burns Wear protective glove...

Page 126: ...d 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 black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil i...

Page 127: ...xtremely 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 protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Never go under the vehicle while it s inclined WARNING ...

Page 128: ...ng screw and remove the screen from the end of the muffler 2 Use a non synthetic brush to clean the arres tor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Replace a worn or damaged screen 4 Reinstall the screen Torque the screw to 5 7 ft lbs 7 9 Nm Reducer Retaining Screw Screen Muffle...

Page 129: ...restarting 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 trailer or towing vehicle Do not perform the following procedures if you don t feel completely capable or if you sus pect that water has entered the fuel tank likely if the water was deep or if the ATV ...

Page 130: ... WARNING 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 following steps 5 Intermittently and briefly touch the starter button in half second intervals to SLOWLY rotate the engine three or four times Fluid will eject from the spark plug hole continued on follow...

Page 131: ...e 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 move the ATV promptly to a trailer or towing vehicle NOTICE If water isn t removed promptly from a submerged ATV rust will form in precision components gears bearings the cylinder and other areas and r...

Page 132: ...ed battery is already filled with electrolyte and has been sealed and fully charged at the factory Never pry the sealing strip off or add any other fluid to this battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the 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 ...

Page 133: ...rged and store it out 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 Disconnect the hold down strap securing the battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Lift the battery out of the ATV ...

Page 134: ...battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 1 Place the battery in the battery holder 2 Connect and tighten the red positive cable first 3 Connect and tighten the black negative cable last 4 Attach the hold down strap 5 Verify that cables are properly routed ...

Page 135: ...e battery WARNING An overheated 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 The battery may be recharged without removing it from the vehicle Attach cables in the fol lowing order 1 Attach the positive cable clamp to the positive battery terminal 2 At...

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 using an automatic charger such as the Polaris Battery Tender refer to the manufac turer s instructions for recharging When using a constant current charger use the guidelines on the following page for...

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 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At leas...

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 when replacing tires Always ensure that all nuts are torqued to specification Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less WARNING 1 8 3 mm ...

Page 139: ...omponent 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 slightly 3 Elevate the side of the vehicle by placing a suitable stand under the frame 4 Remove the wheel nuts and remove the wheel Bolt Location Size Torque Specification Front 3 8 30 35 ft lbs 40 47 Nm R...

Page 140: ... 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation 3 Install the wheel bolts and finger tighten them 4 Lower the vehicle to the ground 5 Securely tighten the bolts to specification See page 136 Valve Stem ...

Page 141: ...ating the vehicle If a boot is torn punctured or leaking fluid see your Polaris dealer for service or replacement After Operating Inspect the boots after operating the vehicle If a boot is bulging or ballooned perform the boot burping procedure on page 139 Good Boot Bulging Boot ...

Page 142: ... 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 shaft before returning the boot to the boot groove Use caution not to allow excess air back into the system when reinstalling the boot 4 Reinstall the boot clamp 1 2 ...

Page 143: ...ystem 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 master cylinder is in a hori zontal position 2 Remove the two cover screws the cover and the rubber boot 3 Fill a bleeder syringe 1 with the recommended hydraulic clutch oil 1 2 3 ...

Page 144: ...n the master cylinder without producing bubbles TIP 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 ...

Page 145: ...42 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 143 1 16 1 8 1 5 3 mm ...

Page 146: ... adjustment procedures exactly 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back an...

Page 147: ...s 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 or death Maintain brake fluid at the recommended level Do not overfill Both brakes are self adjusting but the following checks are recommended to keep the brake systems in good operating condition Ch...

Page 148: ...em 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 brake disc spline and pad wear surface for excessive wear Pads should be changed when worn to 3 64 1 mm 3 64 1 mm ...

Page 149: ...d adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle on a level surface Ensure the vehicle is at the proper ride height by placing a rider on the vehicle 2 Place the handlebars in a straight ahead position Secure the handlebars in this position 3 Place a chalk mark on the center line of the front tires approximately 10 25 4 cm from the floor or as close to the h...

Page 150: ...ine 6 Measure the distance between the marks and record the measurement 2 7 Subtract measurement 2 from measure ment 1 The difference is the vehicle toe alignment 8 The recommended toe alignment is 0 to 1 16 0 1 6 mm toe out This means that the front measurement should be 0 to 1 16 0 1 5 mm greater than the rear mea surement 9 If you discover improper alignment see your Polaris dealer for service ...

Page 151: ...o remove slack at the top side of the chain At the center point of the top side of the chain there should be 1 4 3 8 6 9 mm deflection Use the following procedure if the chain needs adjust ment TIP The chain has a press on master link A chain tool must be used if it s necessary to remove the chain for service 1 Loosen the upper and lower pivot mounting bolts 1 2 Thread the chain adjusting bolt 2 i...

Page 152: ...ainst the bolt heads If not tighten the bolts to 28 ft lbs 38 Nm 6 Bend the retaining tabs tightly against the flat edges of the bolt heads If a tab cannot be aligned with a flat edge it should be bent around a point of the bolt head TIP If a retainer tab does not align with the flat edge of a bolt head the bolt can be tightened to a maximum of 38 ft lbs 51 Nm 1 2 Proper splicelink clip opening po...

Page 153: ...xactly 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 do not contact the gas tank or any other part of the machine when turned fully to the left or right 3 Torque the two front bolts to 10 12 ft lbs 14 16 Nm then torque the two rear bolts A gap of up to ...

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 Camber and Caster The camber and caster are non adjustable ...

Page 155: ...by placing a suitable stand under the frame 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 lower front bumper bolt Note this measurement for later use 5 Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars ...

Page 156: ...ly 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 75 and 4 inches 9 5 10 2 cm 9 If the number is less than 3 75 inches 9 5 cm decrease the front spring preload see page 154 and repeat all steps If the number is higher than 4 inches 10 2 cm increase ...

Page 157: ... to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments ...

Page 158: ...end 2 Loosen the jam nut 3 Turn the adjusting ring clockwise to increase preload Turn the ring counter clockwise to decrease preload 4 Tighten the jam nut firmly against the adjusting ring 5 Measure the preload of the left and right shocks Make sure both shock measurements are equal Adjusting Ring lower Jam Nut upper Increase Preload Decrease Preload ...

Page 159: ...ngine 3 Elevate the rear of the vehicle by placing a suitable stand under the frame 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 rear lower control arm pivot bolt Note this measurement for later use ...

Page 160: ...uspension 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 measurement The difference should be between 4 25 and 4 5 inches 10 8 11 4 cm 10 If the number is less than 4 25 inches 10 8 cm decrease the rear spring preload on both shocks see page 158 and repeat all steps...

Page 161: ...r of the vehicle off the ground to allow the suspension to fully extend 2 Loosen the jam nut 3 Turn the adjusting ring clockwise to increase preload Turn the ring counter clockwise to decrease preload 4 Tighten the jam nut firmly against the adjusting ring 5 Measure the preload of the left and right shocks Make sure both shock measurements are equal Adjusting Ring lower Jam Nut upper Increase Prel...

Page 162: ...rewdriver to make adjustments To set the shock at the firmest setting turn the screw clockwise until it stops fully closed position From this position turn the screw counter clockwise to decrease compression damping Setting Compression Damping Softest 24 clicks from closed Factory 8 clicks from closed Firmest 2 clicks from closed Compression Adjustment ...

Page 163: ...ild 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 to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean...

Page 164: ...eaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish ...

Page 165: ...ning 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 seals Brakes Cab and body panels Labels and decals Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or e...

Page 166: ...ys use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Storage NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Exterior Make necessary repairs and clean the vehicle as recommended See ...

Page 167: ...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 Chart beginning on page 85 Transmission Oil Engine Oil Coolant test strength fill Brake Fluid Clutch Fluid ...

Page 168: ... 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 engine Turn the fuel valve off 5 Start the engine Allow the engine to operate until it stops 6 Drain the carburetor bowl See page 113 7 Remove the spark plug Pour approximately 5 cc of engine oil into t...

Page 169: ...ke 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 ground 4 Cover the vehicle with an appropriate cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation ...

Page 170: ...Stop the engine 2 Place the transmission in first gear 3 Lock the parking brake 4 Remove the key to prevent loss during transporting 5 Secure the fuel cap oil cap and seat 6 Turn the fuel valve off 7 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope ...

Page 171: ... Alternator Output 200 w 3000 RPM Wheelbase 51 in 130 cm Compression Ratio 11 1 Ground Clearance 11 5 in 29 cm Starting System Electric Min Turning Radius 67 in 170 cm Carburetor Keihin FCR MX 39mm Engine Oil Capacity 1 7 qts 1 6 l Ignition System CDI Coolant Capacity 2 25 qts 2 1 l Ignition Timing 25 3 3500 RPM in neutral Engine ES51KLE Spark Plug Type NGK DCPR8E Displacement 510 cc Spark Plug Ga...

Page 172: ...o 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 Taillights LED Gear Ratio Reverse 2 429 Brakelight LED ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above 0 1800 0 6000 Main Jet 158 Needle Clip Position 4 Main Jet 148 Needle Clip Position...

Page 173: ...2W 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 2871460 Starter Drive Grease 2 oz 2871329 Dielectric Grease Nyogelt 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz 1350046 Rear Shaft Grease 30 g ...

Page 174: ... Number Description Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2876335 Hydraulic Clutch Oil qt ...

Page 175: ...s 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 the fuel valve on If fuel leaks out clean the carburetor If no fuel leaks out clean the fuel valve Clogged fuel valve or filter Inspect and clean or replace Old or non recommended fuel Replace with n...

Page 176: ... 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 your Polaris dealer Throttle ETC switch not opening Adjust throttle freeplay The plug connection of the CDI unit pulse generator or ignition coil has oxidized Clean the plug connection and treat wit...

Page 177: ...e 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 octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs ...

Page 178: ...Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Exhaust leak Inspect system for leaks see your Polaris dealer Incorrectly installed spark plug wire See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer ...

Page 179: ...is 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 recommend...

Page 180: ...logged 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 Disassemble carburetor and clean the jets Other mechanical failure See your Polaris dealer ...

Page 181: ...non 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 Inspect clean and or replace spark plugs Fuel is very high octane Replace with recommended octane fuel Incorrect jetting See your Polaris dealer Plugged dirty or wet air filter Clean pre filter repl...

Page 182: ...ve 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 oil in system Check oil level maintain at recommended level Use of non recommended oil too thin Replace with a recommended oil ...

Page 183: ...pted 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 See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer ...

Page 184: ...n 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 gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC Old or non recommended fuel Replace with recommended fuel ...

Page 185: ...lant 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 Foam has formed in cooling system Drain and replace coolant with recommended coolant Bent cooling hose Shorten or replace hose Defective thermostat or thermoswitch See your Polaris dealer Blown fan ...

Page 186: ...uel supply Clean fuel system and carburetor Float leaks Replace the float Clogged dirty or wet air filter Inspect and clean or replace Faulty exhaust system Check system for damage see your Polaris dealer Valve gap is too small Adjust valve gap Faulty ignition timing See your Polaris dealer ...

Page 187: ...olaris 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 record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed ...

Page 188: ...rosion 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 are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE ...

Page 189: ...S 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 Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law ...

Page 190: ...sistance 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 are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Po...

Page 191: ... 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 bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s au...

Page 192: ...r 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 the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the desti...

Page 193: ...red 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 Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions ca...

Page 194: ...or 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 whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatm...

Page 195: ...ON 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 limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not c...

Page 196: ...r manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 3 Hours Break in 15 30 45 ...

Page 197: ...194 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 60 90 ...

Page 198: ...195 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 199: ...196 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 200: ...149 Chain Tension Inspection 149 Cleaning 160 162 Clothing 14 Clutch Fluid 43 Clutch Lever 42 Clutch System Bleeding 140 141 Compression Damping Rear 159 Consumer Product Safety 11 Coolant Level Radiator 108 Coolant Level Recovery Bottle 107 Cooling System 106 109 Cooling System Bleeding 109 D Deceleration 55 Driving Downhill 75 Driving in Reverse 82 Driving on a Sidehill 74 Driving on Slippery Su...

Page 201: ...eadlight Assembly 118 Headlights 41 Helmet 13 I Idle Speed 112 Indicator Lights 40 Instruction Operating 16 J Jetting 114 169 K Key Switch 39 K Turn 76 L Lights 40 41 115 119 Brake Light 119 Headlight Adjustment 115 Headlight Assembly 118 Headlights 41 Indicator Lights 40 M Main Key Switch 39 Maintenance Chart 85 95 Making Turns 69 Manual Shift 52 55 Master Cylinder 48 49 Modifications 12 O Oil Ch...

Page 202: ... Handling Gasoline 17 Hot Exhaust Systems 33 Improper Cargo Loading 31 Improper Hill Climbing 23 Improper Reverse Operation 28 Improper Tire Maintenance 28 Improper Modifications 29 Jumps and Stunts 22 Operating a Damaged ATV 32 Operating at Excessive Speed 21 Operating on Frozen Water 32 Operating on Pavement 20 Safety Warnings 15 33 S Operating on Public Roads 20 Operating on Slippery Terrain 27...

Page 203: ... Switch 39 Main Key Switch 39 Reverse Lock Out Switch 54 Start Button 39 T Throttle Cable Freeplay 143 Throttle Lever 44 45 Throttle Lever Freeplay 142 Tires 135 Installation 137 Removal 136 Tread Depth 135 Wheel Hub Tightening 136 Toe Alignment 146 147 Trail Etiquette 65 Transporting the ATV 167 Tread Lightly 64 Turning Around on a Hill 76 77 V Vehicle Identification Numbers 8 Vehicle Immersion 1...

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Polaris 2009 Outlaw 525 IRS, Owner'S Manual

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