Polaris 2010 OUTLAW 525 IRS Owner'S Manual Download Page 96

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Fuel Used

in gallons (liters)

Upper steering post (1)

6 M

Inspect; tighten fasteners; grease after

washing ATV/driving in water

Front A-Arms (2)

6 M

Inspect; tighten fasteners; grease

(also after washing ATV or driving

in water)

Stabilizer Bar (3)

6 M

Grease

Rear Control Arm Needle

Bearings (4)

12 M

Disassemble; clean; inspect bearings/

seals; grease; reassemble

Summary of Contents for 2010 OUTLAW 525 IRS

Page 1: ...t type recreational and competitive use by operators with advanced skills and substantial experience Operation is prohibited for anyone under 16 years of age Read this manual carefully It contains imp...

Page 2: ...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 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...ain and in turns avoid paved surfaces pavement may seriously affect handling and control without proper training or instruction at speeds too fast for your skills or the conditions on public roads a c...

Page 5: ...1 Visit us at www polarisindustries com...

Page 6: ...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 i...

Page 7: ...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 8: ...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 9: ...ion 6 Safety 10 Features and Controls 38 Operation 58 Emission Control Systems 83 Maintenance 85 Specifications 168 Polaris Products 170 Troubleshooting 172 Declaration of Conformity 184 Warranty 187...

Page 10: ...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 11: ...r driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV...

Page 12: ...es 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 vehicl...

Page 13: ..._____________________________ Frame Vehicle Identification Number 1 ______________________________________________________ Engine Serial Number 2 ______________________________________________________...

Page 14: ...igible family members This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this informatio...

Page 15: ...nded 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 INFORMA...

Page 16: ...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 17: ...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 18: ...gs 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 o...

Page 19: ...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 20: ...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 21: ...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 22: ...scribed 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 pro...

Page 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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...

Page 29: ...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 30: ...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 31: ...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 32: ...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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...38 Features and Controls Start Button Engine Stop Switch Main Key Switch...

Page 43: ...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 44: ...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 45: ...s 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 t...

Page 46: ...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 47: ...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 170 for the part numbers of Polaris products 1 Position the vehicle on a...

Page 48: ...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 49: ...ot 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 procedu...

Page 50: ...ocated 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 ap...

Page 51: ...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 52: ...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 53: ...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 54: ...d 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...

Page 55: ...t 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...

Page 56: ...ext 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...

Page 57: ...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 disengag...

Page 58: ...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 59: ...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...

Page 60: ...tings 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 fuel with ethanol content greater tha...

Page 61: ...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 62: ...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 63: ...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 64: ...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...

Page 65: ...er 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 lig...

Page 66: ...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 67: ...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 68: ...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 69: ...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 70: ...e 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...

Page 71: ...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 72: ...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 r...

Page 73: ...on 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 tu...

Page 74: ...l or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause ski...

Page 75: ...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 76: ...mproper 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...

Page 77: ...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 78: ...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 79: ...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 whi...

Page 80: ...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 81: ...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...

Page 82: ...a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the...

Page 83: ...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 84: ...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 bot...

Page 85: ...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 86: ...es 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...

Page 87: ...with the USFS standard 5100 1c Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in...

Page 88: ...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 complian...

Page 89: ...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...

Page 90: ...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 91: ...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 92: ...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 93: ...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 94: ...ir 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...

Page 95: ...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 96: ...per 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 S...

Page 97: ...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 98: ...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 99: ...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 100: ...rmance 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 re...

Page 101: ...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 leve...

Page 102: ...ation 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 e...

Page 103: ...dle 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...

Page 104: ...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 105: ...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 n...

Page 106: ...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 107: ...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 108: ...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 109: ...lug 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...

Page 110: ...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 111: ...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 112: ...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 113: ...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 114: ...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 so...

Page 115: ...111 Maintenance Air Filter Systems Step 3 Step 5 Step 4 Step 7 Step 6...

Page 116: ...ll 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 i...

Page 117: ...aintenance 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...

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: ...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...

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

Page 124: ...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 125: ...ove 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 Unp...

Page 126: ...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 127: ...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 128: ...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 129: ...g 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...

Page 130: ...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 131: ...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 follo...

Page 132: ...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 133: ...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 134: ...ged 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 se...

Page 135: ...attery 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 re...

Page 136: ...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 b...

Page 137: ...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 138: ...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 139: ...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 140: ...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 141: ...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...

Page 142: ...ting the vehicle If a boot is torn punctured or leaking fluid see your Polaris dealer for service or replacement After Operating Inspect the boots after operating the vehicle If a boot is bulging or b...

Page 143: ...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 sha...

Page 144: ...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 145: ...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 s...

Page 146: ...2 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...

Page 147: ...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...

Page 148: ...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 149: ...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 150: ...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...

Page 151: ...ne 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 t...

Page 152: ...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...

Page 153: ...inst 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...

Page 154: ...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 155: ...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 156: ...y 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...

Page 157: ...y to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 Subtract the step 8 measurement from the step 4 measurement The difference should be between 3...

Page 158: ...to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both th...

Page 159: ...nd 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 th...

Page 160: ...gine 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 fr...

Page 161: ...spension 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 measuremen...

Page 162: ...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...

Page 163: ...ewdriver 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 compr...

Page 164: ...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 165: ...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 166: ...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 167: ...s 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 perio...

Page 168: ...ir 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...

Page 169: ...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 170: ...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 171: ...top the engine 2 Place the transmission in first gear 3 Lock the parking brake 4 Remove the key to prevent loss during transporting 5 Secure the fuel cap oil cap and seat 6 Turn the fuel valve off 7 A...

Page 172: ...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 Eng...

Page 173: ...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 Reve...

Page 174: ...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 175: ...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 176: ...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 177: ...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 178: ...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 179: ...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 180: ...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 181: ...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 182: ...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 183: ...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 184: ...ted fuel supply Clean fuel system and carburetor Clogged dirty or wet air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure S...

Page 185: ...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 186: ...ant Check levels and fill as needed check for leaks Insufficient air flow due to slow operation Operate at a faster speed to increase air flow Cooling system has not been bled Bleed the cooling system...

Page 187: ...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 188: ...below conform to the essential health and safety requirements applicable to off road all terrain vehicles APPLICABLE EUROPEAN DIRECTIVES TEST EVALUATION METHODS 98 37 EC as amended Machinery Directive...

Page 189: ...008 2009 2010 76 8 ___BA32__ TRAIL BLAZER 330 2008 2009 2010 76 8 ___CA32__ TRAIL BOSS 330 2008 2009 2010 76 8 ___BA50__ SCRAMBLER 500 2008 2009 2010 79 6 ___GJ45__ OUTLAW 450 2008 2009 2010 80 7 ___G...

Page 190: ...SPORTSMAN 850 EFI 2009 2010 80 4 ___RH50__ ___HH50__ RANGER 500 EFI 4X4 2009 2010 76 5 ___HH76__ RANGER 800 EFI 4X4 2010 76 5 ___WH76__ RANGER 800 EFI CREW 2010 76 5 ___HR__ RANGER 800 6X6 2010 76 5 _...

Page 191: ...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 192: ...ized parts In addition this war ranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery mate rial corrosion or defects in parts components or the ATV...

Page 193: ...d part of normal maintenance or part of completing an effective repair The following items are excluded from warranty coverage in the event of a warranty claim Spark Plugs Lubricants such as oil greas...

Page 194: ...as been damaged by abuse accident fire or any other casualty not determined a defect of materials or workmanship This warranty does not cover the use of unauthorized lubricants chemicals or fuels that...

Page 195: ...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 196: ...ey 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...

Page 197: ...s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorize...

Page 198: ...f Purchased From A Private Party If you purchase a Polaris product from a private citizen to be kept and used outside of the country in which the vehicle was originally purchased all warranty coverage...

Page 199: ...ons The warranty period for this emissions certified vehicle starts on the date the vehicle is first purchased and con tinues for a period of 250 hours of engine operation 2500 kilometers 1550 miles o...

Page 200: ...s As related to the evaporative emission control system Air induction system Ignition system Fuel system Exhaust gas recirculation systems Aftertreatment devices Sensors Crankcase ventilation valves E...

Page 201: ...ENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUD...

Page 202: ...warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which Polaris has no responsibility or by acts of God Any qualified repair...

Page 203: ...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 204: ...200 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 60 90...

Page 205: ...201 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 206: ...202 Maintenance Log DATE SERVICE INTERVAL HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 207: ...49 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 Radiat...

Page 208: ...adlight 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...

Page 209: ...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...

Page 210: ...Engine Stop 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 1...

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Polaris 2010 OUTLAW 525 IRS, Owner'S Manual

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