Polaris 525 IRS manual

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A card containing importan t A TV safety information sh ould be attached to the owner's manual on the next page. If you cann ot locate this card, or if it has been removed, please ca ll 1-800-342-3764 for assista nce. W ARNING The engine exhaust from this product contains chemicals known to the State of Ca lifornia to cause cancer , birth defe[...]

1 Visit us at www .polarisindustries.com[...]

2 POLARIS and POLARIS TH E W A Y OUT are register ed t rademarks of Polari s Industries Inc. Copyright 2007 Polaris Sales Inc. All in formation contained within this publication is based on the latest p roduct information at the time of publicat ion. Due to constant improvements in th e design and quality of production components, some minor discre[...]

3 We l c o m e Thank you for purchasin g a Polaris vehicle, and welcome to our world-wide family of Polaris owners. W e proudly produce an exciti ng line of utility and recreational products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles[...]

4 We l c o m e W e believe Polaris sets a standard of excellen ce for all utility and re creational vehicles man- ufactured in the worl d today . Many years of experience have gone into the engineering, design, and developmen t of your Polaris vehicl e, making it the finest machine we 've ever produced. For safe and enjoyab le operation of you[...]

5 T able of Contents Know Y our V ehicle . . . . . . . . . . . . 6 Safety Decals . . . . . . . . . . . . . . . . 8 Safety . . . . . . . . . . . . . . . . . . . . . 12 F eatures and Controls . . . . . . . . 50 Break-In P eriod . . . . . . . . . . . . . . 70 Pre-Ride Inspection . . . . . . . . . . 72 Operation . . . . . . . . . . . . . . . . . . 74 E[...]

6 Know Y our V ehicle The high perform ance engine in yo ur vehicle re q u i re s routine service to maintain the highest level of performance and reliability . Please read and follow the “B reak-In Period” and “Maintenance” sections of your Owner ’ s Manual carefully . Failure to perform the recom- mended procedures at the servi ce inter[...]

7 Know Y our V ehicle V ehicle Identification Numbers V ehicle Model Number: _________________________________________________________________ ___ F rame V ehicle Identifica tion Number (1): ___________________________________________________ ___ Engine Serial Number (2): ________________________________ __________________________________ Key Numbe[...]

8 Safety Decals W arning decals have been placed o n the vehicle for your prot ection. Read and follow the instructions on each decal carefully . If any of th e decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle. If any decal becomes illegible or comes off, contac[...]

9 Safety Decals General Warning WARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gear . Never use on public roads. Ne ver carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instructio n • at speeds too fast for yo ur skills or the conditions[...]

10 Safety Decals Age 16 W arning WARNING Operating this A TV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7172559 Sport A TV W arning WARNING This A TV may exceed the performance of other A TVs you may have ridden in the past. This category S (Sport) A TV is a high [...]

11 Safety Decals No P assenger W arning WARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. 7172566 Tire Pressure/Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERL OADING can cause loss of control, resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 4[...]

12 Safety Riding Gear Always wear clothing suited to the type o f riding. A TV riding requires special prot ective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prev ent a severe head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved[...]

13 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses fo r eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet fac e shield. Polaris recommends wearing approved Personal Protec tive Equipment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su re pr[...]

14 Safety Operator Safety Operator Restrictions/Age Restrictions This vehicle is an ADUL T VEHICLE ONL Y . Op eration is prohibited for anyone under 16 years of age. This category S (Sport) A TV 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 subs[...]

15 Safety Operator Safety Safety T raining A TV safety training is a top priority for Polaris. When you purchased yo ur new A TV , your dealer instructed you on the authorized A TV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and your[...]

16 Safety Operator Safety The following signal words and symbols appear throu ghout this manual an d on your vehicle. Y our safety is involve d when these words and symbols are used. Become familiar with their meanings before r eading the manual. The safe ty alert symbol , on your vehicl e or in this manual, alerts you to the potential for injury .[...]

17 Safety Operator Safety • Read this manual and all labels carefully . Follow all operating procedures. • Never operate an A TV without proper instruction. T ak e a training course. Pu r- chasers of a new Polaris A TV a nd age eli- gible family members are entitled to take the A TV RiderCourse sm . Contact A TV Enrollment Express at (8 00) 887[...]

18 Safety Operator Safety • Never operate an A TV on a public street, road or highway , including a dirt or gravel road. • Never operate an A TV without wearing an approved helmet that fits properly . Always wear eye protection (gog gles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. • Never consume alcohol or[...]

19 Safety Operator Safety • Never operate on excessively rough, slip- pery or loose terrain. • Always follow proper turning procedures as described in this manual. Practice turn- ing at low speeds before attempting to turn at faster speeds. Do not turn at e xces- sive speeds. • Always have the A TV inspected by an authorized Polaris dealer if[...]

20 Safety Operator Safety • Always follow proper procedures for crossing the side of a hill. A void hills with excessively slippery or loose sur- faces. Shift your weight uphil l. Never attempt to turn th e A TV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. A void crossing the side [...]

21 Safety Operator Safety • Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of con- trol. • Always check for obstacles before oper- ating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always[...]

22 Safety Operator Safety • Always check for obstacles or people behind the A TV before operating in reverse. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for your A TV , and always main- tain proper tire pressure. • Never modify an A TV through imp[...]

23 Safety Operator Safety Equipment Modifications W e are concerned for the safety of our custom ers and for the general public. Therefore, we strongly recommend that consumers do not in st all on a Polaris A TV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any [...]

24 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV wi thout proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operato r does not know how to operate the A TV properly in diffe rent situations and on different types of terrain. HOW TO A VOID THE HAZARD Beginning and inexperienced oper at[...]

25 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to follow the skill and experience recommendation s for this A TV . WHA T CAN HAPPEN Severe injury and/or death could occur if a begi nner or inexp erienced driver operates this A TV . HOW TO A VOID THE HAZARD Only operators with advanced sk ills and substantial experien ce should ope[...]

26 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to follow the age recomme ndations for this A TV . WHA T CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates this A TV . Even though a child may be within the recommended age grou p for operating some A TVs, he/she may not have th[...]

27 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Carrying a passe nger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the A TV , which could cause an accide nt and injury to the operator and/or passenger . HOW TO A VOID THE HAZARD Never carry a passenger . The purpose of t[...]

28 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating an A TV on pave d surfaces, includin g sidewalks, paths, parking lots, and dri veways. WHA T CAN HAPPEN A TV tires are designed for off- road use. Operating on paved surfaces may adversely affect the hand ling of the A TV and could result in loss of control, accident, and/or injury . [...]

29 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with anothe r vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any pu blic street, road or highway , including dirt and gravel roads. In many states it's illegal to operate A TVs on[...]

30 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV without wearin g an approved helmet, eye protection and protective clothing. WHA T CAN HAPPEN Operating an A T V without an approved helmet in creases the risk of a severe head injury or death in the event of an accident. Operating without e ye prot ecti on could result in a[...]

31 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV after consuming alcoh ol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and ope rator balance and perception could be affected. Consuming alcohol and/or drugs before or whi le operating an A[...]

32 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the A TV at excessive speeds. WHA T CAN HAPPEN Excessive speed increases the operator's chance of losing control of the A TV , which can result in an accident causing severe injury or death. HOW TO A VOID THE HAZARD Always operate the A TV at a spee d that's proper for the terra[...]

33 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving.[...]

34 Safety Operator Safety WAR N I N G POTENTIAL HAZARD T owing or pulling an object behind th e A TV . WHA T CAN HAPPEN A wagon, sled or other obje ct towed behi nd an A TV does not have b rakes or steering. The object may overturn or collide with other objects and cause serious injuries. HOW TO A VOID THE HAZARD Never tow or pull an object behind [...]

35 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to use extra caution when operating the A TV on unfamiliar terrain. WHA T CAN HAPPEN Unfamiliar terrain may contain hid den rocks, bumps, or holes that could cause loss of control or overtu rn. HOW TO A VOID THE HAZARD T r avel slowly and use extra caution when operating on unfamiliar[...]

36 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to use extra caution when operati ng on excessively rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on excessively rough , slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO A VOID THE HAZARD Do[...]

37 Safety Operator Safety WARNING POTENTIAL HAZARD T urning improperl y . WHA T CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster s[...]

38 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the A TV . If the operator's foot is not fi rmly planted on t he footpeg[...]

39 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating on exce ssively steep hil ls. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. Never operate the A TV on hills steeper than 25 degrees 25 ° . >25 °[...]

40 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Climbing hills improperly . WHA T CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for climbing hills as describe d in the Owner's Manual beginning on page 82. Always check the terrain carefully be fore asce[...]

41 Safety Operator Safety WAR N I N G POTENTIAL HAZARD T r aveling downhill improperly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hill s as described in the owner's manual. NOTE: A special technique is required when braking[...]

42 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHA T CAN HAPPEN Improperly crossing or turning as hills could cause lo ss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the A TV around on any hill until you've mastered the turning technique (on level ground) as describe[...]

43 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Stalling, rolling backwards or improperly dismountin g while climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill. Apply the front brakes gradually (right le ver). [...]

44 Safety Operator Safety WARNING POTENTIAL HAZARD Skidding or sliding. WHA T CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly , the A TV could overturn. HOW TO A VOID THE HAZARD On slippery surfaces su ch as ice, trave l slowly and use extra caution to reduce the chance of skidding or sliding out [...]

45 Safety Operator Safety WARNING POTENTIAL HAZARD Operating on frozen b odies of water . WHA T CAN HAPPEN Severe injury or death can result if the A TV and/or the operator fall through the ice. HOW TO A VOID THE HAZARD Never operate the A TV on a fro zen body of water . WAR N I N G POTENTIAL HAZARD Operating this A T V with improper tires, or with[...]

46 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV through deep or fast-flowin g water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowin g water . If it's unavoidab le[...]

47 Safety Operator Safety WARNING POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo. WHA T CAN HAPPEN Overloading or carrying/towing cargo can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never haul cargo or tow a load with this A TV . Never exceed the stated load capac[...]

48 Safety Operator Safety WARNING Safe operation of this rider -active vehicle requires good judge ment and physical skills. Persons with cognitive or physical disabili ties who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or de ath. WAR N I N G Operating a damaged A TV can result [...]

49 Safety Operator Safety WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall gr ass, especially dry grass. WAR N I N G L[...]

50 F eatures and Controls Start Button Engine Stop Switch Main Key Switch[...]

51 F eatures and Controls Main K ey Switch The main key switch must be in the RUN position to start the engine. See page 75 for starting procedures. Start Button Press the start button to engage the starter . Alwa ys release the start button promptly w hen the engine starts. NOTE: If the starter fail s to engage, replace the blown fuse or see your [...]

52 F eatures and Controls Lights Indicator Lights An illuminated light in the indicator window will alert you to the follow- ing conditions. • Hot engin e • Reverse gear is selected • Neutral gear is selected NOTE: If indicator lights fail to oper- ate, check connections. See your Polaris dealer for inspec- tion of the capacitor and volt- age[...]

53 F eatures and Controls Lights Headlights Use the light switch to turn the lights on and off and to switch the lights from high beam to low beam. NOTE: The lights won't work unless the key is in the ON position and the engine stop switch is in the RUN position. WAR N I N G Operating the A TV on streets or roads, especia lly in darkness, coul[...]

54 F eatures and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar . Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears. The clutch is self-adjusting, but lever position can be changed to fit the operator’ s hand. T urn the adjusting knob counterclockwi[...]

55 F eatures and Controls Clutch Fluid The clutch fluid master cylinder is located on the left handlebar . Check the fluid level in the reservoir before each ride. The level should be 4mm below the upper edge of the re servoir . Do not overfill. Polaris recommends the use of KTM Hydraulic Clutch Oil. Do not use brake fluid. Do not mix clutch fluid [...]

56 F eatures and Controls Throttle Lever The throttle lever is loca ted on the right handlebar . Squeeze the lever toward the handlebar to increase engine speed and ve hicle movement. Engine speed returns to idle when the leve r is released. See page 159 for throttle adjustment procedures. NOTE: F uel is injected into the intake passage each time t[...]

57 F eatures and Controls Throttle Lever This A TV is equipped with an Electronic Th rottle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open posi- tion when the operator re leases the throttle lever , the engine will stop. WAR N I N G The Electronic Throttle Control (E [...]

58 F eatures and Controls Foot Brake The foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. If the rear wheels slide wh ile using the foot brake, reduce brake pedal pressure to brake the wheels without skidding. Check the brake fluid leve l frequently for the foot brake system. The reservoir is locat[...]

59 F eatures and Controls Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar . Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes. Always test brake lever travel and master cylin- der fluid level before riding. When squ[...]

60 F eatures and Controls Master Cylinder/Brake Fluid Under normal operation, the diap hragm extends in to the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure pro[...]

61 F eatures and Controls Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder be fore each ride. If the fluid level is low add DOT 4 brake fluid only . Do not overfill. See pa ge 188 for the part nu mbers of Polaris prod- ucts. NOTE: When checking the fl uid level, the master cylinder cover must be level. Hand Brake Fluid Level[...]

62 F eatures and Controls Pa r k i n g B r a k e 1. Place the transmission in first gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock down to engage the lock . Release the brake lever . 4. T o release the pa rking brake lock, squeeze and release the brake lever . The lock will au[...]

63 F eatures and Controls Pa r k i n g B r a k e Important Safeguards • The parking brake may relax if left o n for a long period of time. Alway s block the wheels to prevent rolling. • Always block the wheels on the downhill side of the A TV if leaving it parked on a hill. Another option is to park the A TV in a sidehill position. • Never de[...]

64 F eatures and Controls Manual Shift Shift P edal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the tr ansmission to the next gear in the shifting sequence. The pedal automa tically returns to a horizontal position when released. T o upshift to a higher gear , place the toe of your b oot un[...]

65 F eatures and Controls Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gea rs. 1. When starting from a stopped p osition, place the transmission in neutral. 2. Squeeze and hold the brake lever . NOTE: Do not squeeze the throttle lever . 3. Squeeze the clutch lever to disengage the clutch. 4. Depress the ge[...]

66 F eatures and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally . 1. Place the transmission in first gear . See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3. Shift down into reverse gear . NOTE: The lock will[...]

67 F eatures and Controls Manual Shift Deceleration T o slow or stop the vehicle , release the thro ttle lever and apply the brakes smoothly and evenly . As the vehicle slows and engine RPM de creases, disengage the clutch and shift to a lower gear . NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear . WAR N I N[...]

68 F eatures and Controls Choke The choke assists in starting a cold engine. The choke knob is located on the left side of the carburetor . Refer to the engine starting procedure on page 75 for correct choke and throttle settings during starting. Fu e l T a n k The fuel tank filler cap is located directly below the handlebar . Polaris recommends th[...]

69 F eatures and Controls F uel V a lve The fuel valve is located on the left side of the A TV . It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main suppl y is exhausted. NOTE: There's about a 5 to 8 mile (8 to 13 km) range on reserve gas. Always re fill the gas tank[...]

70 Break-In P eriod Careful treatment of a new engine and transmis sion will result in more efficient performance and longer life for both. The b reak-in period for your new Polaris A TV is the first three hours of operation, or the time it takes to use 5-6 ga llons (20 liters) of fuel . Do not allow engine speed to exceed 7000 RPM during the break[...]

71 Break-In Period 1. Fill the fuel tank with gasoline. See page 74. 2. Check the oil level. Ad d the recommended oil as needed to maintain the oil level i n the proper range. See page 109. 3. Allow the engine suf ficient time to warm up before operating. 4. Drive slowly at first. Select an open area that allows room to familiarize yourself with ve[...]

72 Pre-Ride Inspection WAR N I N G If a proper inspection is not done before each us e, severe injury or dea th could result. Always inspect the vehicle before ea ch use to ensu re it's in proper operating co ndition. Pre-Ride Checklis t P age Brake systems / lever travel En sure proper operation 58-63 160-161 Brake fluid Ensure prop er level [...]

73 Pre-Ride Inspection Pre-Ride Checklis t P age Coolant (if applicable) Ensure proper level 119 Coolant hoses (if applica ble) Inspect for leaks -- Throttle Ensure smooth operation 56 Indicator lights / switches Ensure operation 52, 53 Engine stop switch Ensure proper operati on 51 Air filter Inspect, clean, re place as needed 122 Air box sediment[...]

74 Operation F uel System WAR N I N G Gasoline is h ighly flammable and e xplosive under certain con ditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outd oors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where re fueling is[...]

75 Operation Starting the Engine The engine can be starte d when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the throttle lever whi le starting the engine. Do not[...]

76 Operation Starting the Engine 1. Shift the transmission to neutral. 2. Lock the parking brake. 3. T u rn the fuel valve on. 4. Sit on the vehicle. 5. Disengage the clutch. 6. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine. 7. Move the en gine stop switch to the RUN position. 8. T urn[...]

77 Operation Starting the Engine NOTE: If starting the engi ne while in gear , apply the hand b rake and squeeze th e clutch lever fully to disengage the clutch. If starting the engine wh ile in neutral , the neutral indicator li ght should be on. If it isn't, disengage the clutch and shift the foot pedal to find neutral. See page 64. 9. Press[...]

78 Operation Driving Procedure 1. Sit upright with both feet on the footpegs and both hands on the h andlebars. 2. Star t the engine and allow it to warm up. 3. Shift the transmission into gear . See page 64. 4. Check your surroun dings and determine your path of travel. 5. Release the parking brake. 6. Slowly depress the throttle with your right t[...]

79 Operation Making T urns Practice making turns at slow speeds befo re attempting to turn at faster speeds. Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater di stance than the inside wheel when turning, and the inside tire slips traction slight[...]

80 Operation Driving on Slippery Surfaces WAR N I N G F ai lure to exercise care when operating on slippery su rfaces can result in loss of tire traction and cause loss of control, acciden t, and serious injury or death . Never apply the brakes during a skid. Do not operate on excessi vely slippery surfaces. Always reduce speed and use additi onal [...]

81 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, 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, sh arp turns, which can cause skids. 3. Correct a skid by tu[...]

82 Operation Driving Uphill WAR N I N G Braking and handling are greatly affecte d when oper ating in hilly terrain . Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25 ° max imum). Use extreme caution when operatin g on hi lls, and follow proper operati ng procedures ou[...]

83 Operation Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void steep hills (25 ° maximum). 3. Keep both feet on the footpegs . 4. T ransfer your weight forward. 5. Proceed at a ste ady rate of speed and throttle opening. 6. Remain al ert and be prepar ed to take emergency action. This m[...]

84 Operation Driving Across Hillsides WAR N I N G Improperly crossing hills or turning on hills can resu l t in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.[...]

85 Operation Driving Across Hillsides If you enter into a situation where sidehilli ng 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 footpe gs. 3. Steer slightly into the hill to maintain direction. NOTE: If the vehicle begins to tip, quickl[...]

86 Operation T urning Around on a Hill If the vehicle stalls while climbi ng a hill, never back it down th e hill! One maneuver that can be used when it's necessary to turn around while clim bing a hill is the K-turn: 1. Keep your body weight uphill. 2. Pull in the clutch lever and apply the front and rear brakes. 3. When completely stopped, s[...]

87 Operation T urning Around on a Hill 6. Reach across th e handlebar and appl y the front brakes to unloc k the parking brake. 7. W ith the front brakes applied, pull in the clutch lever . Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward. 8. W ith the front bra ke[...]

88 Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. T ra nsfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid in slowing. WAR N I N G Excessive speed can ca use loss of co[...]

89 Operation P arking on a Hill or Incline A void parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions: 1. T u rn 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. T u rn the fuel valve off.[...]

90 Operation Driving Through W ater Y our A TV can operate through water with a maximum recommended depth equ al to the level of the footpegs. Follow these proce- dures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual in clines. 3. Proceed slowly , avoiding rocks[...]

91 Operation Driving Through W ater A void operating your A TV through deep or fast flowing water . If the A TV is operated in deeper water th an recommended , it's critical to have it servic ed as outlined in the mainte- nance chart beginning on page 97. Engine oil and all grease f ittings need special attention. NOTE: Avoid operati ng the ve[...]

92 Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the bra kes lightly for stopping. 3. A void turning at sharp ang les. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always look left, right and behin d the A TV before backing.[...]

93 Operation Driving in Reverse This Polaris A TV is equipped with a reverse sp eed limiter . Do not oper ate at full throttle. Use just enough throttle to maintain a desired speed. WAR N I N G F ai lure to use ca ution when operating in reverse can result in se rious injury or de ath. Before shifting into reverse, always check for obstacles or peo[...]

94 Operation Driving Over Obstacles Be alert! Look ah ead and learn to re ad the ter- rain you're traveling on . Be constantly alert for hazards such as logs, rocks and low hang- ing branches. WARNING Severe injury or death ca n result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. T ravel w[...]

95 Emission Control Systems Noise Emission Control System Do not modify the engine, intake or ex haust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requ ire- ments. Operation on Public Lands in the U.S.A . Y our Polaris vehicle has a spa rk arrestor that was tested and [...]

96 Emission Control Systems Crankcase Emission Control System This engine is equipped with a closed cran kcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaus t gases exit through the exhaust system. Exhaust Emission Control System The emissions from the exhaust of this vehicl e are controlled by eng[...]

97 Maintenanc e Periodic Maintenance Chart The high perform ance engine in your vehicle re q u i re s routine service to maintain the highest level of performance and reliability . Please re ad and follow the “Break-In Period” and “Maintenance” sections of your Owner ’ s Manual carefully . Failure to perform the recommended procedures at [...]

98 Maintenance Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer . Record maintenance and service in the Main tenance Log beginning on page 21 1. NOTE: Service and adjustments are crit ical[...]

99 Maintenanc e Periodic Maintenance Chart Maintenance Chart K ey X Perform these operations mo re often under severe use. E Emission-related service (Failure to condu ct 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 Greas[...]

100 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used Brake systems/brake fluid -- Pre-ride -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist. 72 Tires - - -- Wheels/lug nuts -- -- Fr ame fasteners -- -- Coolant -[...]

101 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallon[...]

102 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons (liters) Brake pad wear 10 Monthly -- Inspect regularly 161 Rear sprocket bolts 10 Monthly -- Check torque 166 Battery 10 Monthly -- Check terminals; clean; test 145 X E Air filter 15 Weekly -- Inspect[...]

103 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallon[...]

104 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) X z Upper steering post (1) 45 6 M -- Inspect; tighten fasteners; grease after washing A TV/driving in wate r X z F ront A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease (also after washing A TV [...]

105 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallon[...]

106 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) E Compression ring 90 -- 156 (600) See your dealer or refer to the Dealer Service Manual; measure ring gap and replace if at or below service limit E Oil scraper ring 90 -- 156 (600) Camshaft 90 -- 156 [...]

107 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallon[...]

108 Maintenance Engine Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Periodi c Maintenance Chart beginning on page 97. Po laris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a similar oil desi gned for use in 4-stroke manual clutch A TV and motorcycle applications[...]

109 Maintenanc e Engine Oil Level Check the oil level before each use of the vehicle. If the engine is cold, the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible at the center of the sight glass. A high oil level can cau se engine overh eating, which could result in engine da m[...]

110 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Perform the initial break-in oil change after the fi rst three hours of operation. Always change both oil filters and clea n the oil screens whenever changing oil. NOTE: Change the oil more freq uently on vehicle[...]

111 Maintenanc e Engine Oil Change 1. Position the vehicle on a level surface. NOTE: Remove the skid plate for better access to the oil drain plug and short screen. 2. Star t the engine. Allow it to idle for two t o three minutes. S top the engine. 3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain completely [...]

112 Maintenance Engine Oil Change Cleaning the Short Oil Screen NOTE: Remove the skid plate for better access to the oil drain plug and short screen. Hex Plug View from bottom of vehicle Fr o n t[...]

113 Maintenanc e Engine Oil Change Cleaning the Short Oil Screen 1. Remove the plug at the bottom of the engine. See illustration on preceding page. 2. Remove the short oil screen from the plug. Cl ean 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 [...]

114 Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen plug , 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 simil[...]

115 Maintenanc e Engine Oil Change Cleaning the Long Oil Screen 5. Insert the tool through th e op ening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. 6. Reinstall the plug. T orque to 1 1 ft. lbs. (15 Nm). CA UTION An improperly installed oil screen will function poor[...]

116 Maintenance Engine Oil Change Changing Oil Filters 1. Place a drain pan under the engine. 2. Remove the four oil filter cover screws (1). Remove the co vers. 3. Using circle clip (sna p 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. Chec[...]

117 Maintenanc e Engine Oil Change Changing Oil Filters 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. T ighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fill plug (4). Add 1.7 qts. (1.6 l) of the recommended engine oil (see page 108). Reinstall the fill plug. 9. Star t the engine. Allow it to idle for at lea[...]

118 Maintenance Engine Cooling System The engine coolant level is cont rolled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck , radiator pressure cap and connecting hose. T o ensure that the coolant maintains its ability to protect the engine, we recommend that you completely drain [...]

119 Maintenanc e Engine Cooling System Coolant Level The recovery bottle is locat ed on the right side of the vehicle under the front fend er . The fluid level must be maintained be tween the FULL and ADD marks on the side panel (when the fl uid is cool). As coolant operating te mperature increases, the expanding (heated) excess co olant is forced [...]

120 Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dr y , inspect the level in the radiator and add coolant if n ecessary . The radiator pressure cap is located on the left side of the vehicle. 1. Remove the pre ssure cap. 2. Using a funnel, slowly add coolant as necessary through the radiator filler neck. 3[...]

121 Maintenanc e Engine Cooling System Cooling System Bleeding Bleeding the cooling system is required only if the syst em has been drained for maintenance and/or repair . Always allow the engine to cool sufficiently before removing the radiator pres- sure cap. 1. Remove the pre ssure cap. 2. Using a funnel, slowly add th e recommended coolant. Fil[...]

122 Maintenance Air Filter Systems NOTE: Refer to th e illustrations o n page 123. 1. Remove the seat. 2. Release the airbox cover clips and remove the cover . 3. Loosen the filter clamp. Remo ve the air filter from the box. 4. Locate the retaining spring. 5. Carefully remove the reta ining spring from the filter . 6. Remove the inner and ou ter fo[...]

123 Maintenanc e Air Filter Systems Step 3 Step 5 Step 4 Step 7 Step 6[...]

124 Maintenance Carburetor Normal wear from engine vibrat ions may cause th e carburetor to supply an overly rich fuel mixture. Replace the jet needle and the need le jet after every 180 hours of operation. Idle Speed Carburetor idle adjustments affect engine starting behavior . A proper idle speed of 1500-1600 RPM will result in easier starting. I[...]

125 Maintenanc e Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be ginni ng on page 97. Al ways drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. T u rn the fuel valve off. 2. Place a suitable container under the carburetor [...]

126 Maintenance Carburetor Jetting Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes an d temperatures, certain adjust- ments can be made to improve its operation and driveabilit y . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly r[...]

127 Maintenanc e Lights When servicing a halogen lamp, do n't touch the lamp with bare fingers. Oil from y our skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WAR N I N G Poor lighting while driving can result in severe in jury or death. Headlight and taillight lense s become dirty during normal operation. Was[...]

128 Maintenance Lights Headlight Adjustment 1. Position the vehicle on a level surface with the head- light approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from th e floor to the center of the headlight and make a mark on the wall at the same height. 3. Star t the engine and turn th e headlight switc h to high beam. 4. Observ[...]

129 Maintenanc e Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counter clockwise to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb. 3. Apply dielectric grease to the socket and install the [...]

130 Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see pa ge 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp. 5. Install the new headlamp by inserting the outboard pivot pin in the h[...]

131 Maintenanc e Lights Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboa rd pivot pin of the headlamp. Adjust for approximately 1/16" clearance between the bracket and the edge of the headlight. T ighten the mounting screws. IMPOR T ANT : Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freel[...]

132 Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation b efore each use of the vehicle. 1. T urn the ignition key on. 2. Lightly apply and release the foot bra ke several times. A properly operating rear brake light will immedi- ately flash on and of f with each movement of the brake pedal. 3. If the light doe[...]

133 Maintenanc e F ro nt Cab Removal 1. Remove the left and right cab moun t screws (1). 2. Remove the wire harness connector from the cab. The connec tor is located under the left fender . 3. Remove the fuel tank cover screws (2). 4. Remove the four side panel screws (3). 5. Gently pull the cab upwa rd to disengage it from the stand-off. Place the[...]

134 Maintenance Side P a nel Removal 1. Unlatch and remove the seat. 2. Remove the front cab. 3. Remove the screw securing the side panel. 4. Remove the sid e panel. Side Pa n e l Screw[...]

135 Maintenanc e Rear Cab Removal 1. Unlatch and remove the se at. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove th e cab. 1 3 2[...]

136 Maintenance Spark Plugs Refer to the specifications section beginnin g on page 186 for recommended spark plu g type and gap. Spark plug condition is indicativ e of engine operation. The spark plug firing end condition should be read after the engine has been warmed up an d the vehicle has been driven at high er speeds. Immediately check the spa[...]

137 Maintenanc e Spark Plugs Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator ti p indicates overheating, caused by use o[...]

138 Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right side of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm). Spark Plug[...]

139 Maintenanc e Spark Arrestor Clean-Out T o remove a ccumulated carbon, clean the spark arrestor at the interv als recommended in the Periodic Maintenance Char t beginning on page 97. WAR N I N G F ai lure to heed the fo llowing warnings while servicin g the spark arrestor could result in serious injury or death. Do not perform clean-out immediat[...]

140 Maintenance Spark Arrestor Clean-Out NOTE: Refer to the illustration on page 141. 1. Remove the retaining screw and remove the arrestor from the end of the muf fler . 2. Use a non-syn thetic brush to clean the arr estor screen. A synthetic brush may melt if components are warm. NOTE: If necessary , bl ow debris from the scree n with compressed [...]

141 Maintenanc e Spark Arrestor Clean-Out Arrestor Retaining Screw Screen Muffler[...]

142 Maintenance V ehicle Immersion If your A TV has been subm erged or overturned in water deeper than th e footpeg level, it's critical to dry it promptly and prop erly before starting the engine. Do not perform the following procedures if you don't feel completely capab le, or if you sus- pect that water has entered the fuel tank (lik e[...]

143 Maintenanc e V ehicle Immersion 1. T u rn the fuel valve off. 2. Drain water from the air box and clean the air filter . See page 122. 3. Drain the carburetor bowl. See page 125. 4. Remove the sp ark plug. See page 138. 5. Intermittently and briefly touch the starte r button in half-second intervals to SLOWL Y rotate the engine three or four ti[...]

144 Maintenance V ehicle Immersion 6. Press and hold the starter button for 10 sec ond intervals for about one minute or until water vapor is no longer ejec ting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride insp ection level, water has entered the crankcase. Do not start the engine. T ransport the vehic[...]

145 Maintenanc e Battery The sealed b attery is alread y filled with el ectr olyte and has been sealed and fully charged at the factory . Never pry the sealing strip of f or add any other fluid to this battery . Keep the battery terminals and connections free of corrosion. If cleaning is necessary , remove the corrosion wi th a stiff wire bru sh. W[...]

146 Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remov e the battery from the vehicle, ensure that it's fully charged, 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. Remov[...]

147 Maintenanc e Battery Installation NOTE: Always install a fully cha rged battery . Using a n ew battery that has not been fully cha rged can damage the 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 batter y holder . 2. Connect [...]

148 Maintenance Battery Charging (Sealed Battery) On a sealed battery , the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully char ged battery will register 12.8 V or h igher . If the voltage is less than 12.8 volts, recharge the battery . The battery may be recharged witho ut removing it from the vehicle[...]

149 Maintenanc e Battery Charging (Sealed Battery) When using an automatic charger such as the Polaris Battery T ender , refer to the manufac- turer's instructions for rechargi ng . When using a constant curren t char ger, use the guidelines on the following page for rechar ging. WAR N I N G An overheated battery could explode, causing severe [...]

150 Maintenance Battery Charging (Sealed Battery) NOTE: Always verify battery condit ion before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3 mon ths from date of manufacture None required 75%-100[...]

151 Maintenanc e Tires Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. WAR N I N G Operating your A TV with worn ti res, improperly inflated tires, non-stand ard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain pro[...]

152 Maintenance Wheel Nut T orque Specifications Check the wheel nut torques occasionally and wh en they've been loo sened for maintenance. Wheel Hub Tightening Front wheel bearing tightness an d spindle nut retention are cr itical componen t operations. All service must be performed by yo ur authorized Polaris dea ler . Wheel Removal 1. Stop [...]

153 Maintenanc e Wheel Installation 1. Place the transmission in gear . Lock the parking brake. 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 bo[...]

154 Maintenance Boot Inspection Before Operating Inspect the boot s before operating the v ehicle. If a boot is torn, punctured or leaking flui d, 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 th e boot burping proced ure on page 155. Goo[...]

155 Maintenanc e Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the bo ot two inches toward the center of the vehicle and lift the bo ot away from the shaft to allow excess air to escape (2). 3[...]

156 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Main tenance Chart beginning on page 97. Always bleed the clutch system any time the clutch lever feels unrespo nsive. Always use the recommended fluid when blee ding the clutch system. See page 55. 1. Position the vehicle on a level su[...]

157 Maintenanc e Clutch System Bleeding 4. Remove the bleeder screw (2) from the slave cylinder . 5. Press fluid into the system unti l the fluid runs out of the hole (3) in the master cylinder without producing bub bles. NOTE: Extract fluid from the ma ster cylinder during the process to preven t overflowin g. 6. When finished, remove the bleede r[...]

158 Maintenance Throttle Lever F reeplay Periodically check throttle lever freeplay . Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are need ed, use the procedure on page 159. 1/16 " - 1/8" (1.5 - 3 mm)[...]

159 Maintenanc e Throttle Cable F r eeplay Adjustment 1. Locate the throttle cable at the handlebar . 2. Slide the boots off th e inline cable adjuster sleeve and loosen the locking nut. 3. T urn the adjuster until 1/16" to 1/8" (1.5-3 mm) freeplay is achieved at the thumb lever . NOTE: While adjusting freep lay , be sure to fli p the thr[...]

160 Maintenance Brakes Both brakes are self-adjusting, but the following checks are recomme nded to keep the brake systems in good operating condition. Check more often if brakes are used heavily under nor- mal operation. WAR N I N G An over -full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. [...]

161 Maintenanc e Brakes 1. Always maintain brake fluid at the recommended level. See pages 60-61. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear , damage and loose ness. 5. Check the security and su rface condition of the disc. 6. Inspect the rear brake disc sp[...]

162 Maintenance T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a ne utral toe setting. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahe ad po sition. Use tie straps to secure the handlebars to the rear grab bar so they can't move. 3. Place s[...]

163 Maintenanc e T oe Alignment 4. T ie an elastic string around the stands, ma king sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in fro nt of the vehicle. 5. Measure the distance between the string in front of the rear tires (1) and in front of the front tires (2). If the tw[...]

164 Maintenance Chain T ension Check the amount of cha in slack by moving the vehicle slightly forward to 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 procedure on the foll owing page if the chain need s adjustmen t. NOTE: The chain has a[...]

165 Maintenanc e Chain T ension 1. Loosen the upper and lowe r pivot mounting bolts (1). 2. Thread the chain adjus ting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. T ighten the pivot mounting bol ts to 30 ft. lbs. (40 Nm). 4. T orque the chain adjusting bolt to 17 ft. lbs. (23 Nm). 1 2 Proper splicelink clip opening[...]

166 Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Loosen the four handlebar bo lts. 2. Adjust the handlebar to the desired height. Be sure the handlebars do not contac t the gas tank or any other part of the machine when turned fully to the left or right. 3. T orque the two front bolts to 10-1 2 ft. lbs. ([...]

167 Maintenanc e Steering Inspection Check the steering assembly periodically for loos e nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the stee ring post, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.[...]

168 Maintenance F ront Susp ension Suspension Set-Up 1. Position the vehicle on a level surface. 2. S top the engine. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measure the distance from the ground to the botto[...]

169 Maintenanc e F ront Suspension Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or p ushing down on the su spension. 7. T u rn the handlebars fully to the left and right. 8. W ith the rider still on the vehicle, repeat the measurem ent performed in st[...]

170 Maintenance F ront Susp ension Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. WAR N I N G Uneven adjustment may cause poo r handling of the A TV , which could result in an acciden t and serious injury or death. Always adjust both the left and right sprin g preloads equally or[...]

171 Maintenanc e F ront Suspension Spring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Loosen the jam nut. 3. T u rn the adjusting ring cloc kwise to incr ease preload (1). T urn the ring counter-clockwise to decrease preload (2). 4. T ighten the jam nut against the adjustin[...]

172 Maintenance Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. S top the engine. 3. Elevate the rear of the vehicle by plac- ing a suitable stand under the frame. NOTE: The tires should be bare ly touching the ground and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom[...]

173 Maintenanc e Rear Suspension Suspension Set-Up 5. Remove the stan d and have a rider sit comfor tably on the seat with hands on the handle- bars. 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or p ushing down on the su spension. 7. T u rn the handlebars fully to the[...]

174 Maintenance Rear Suspension When the adjuster screw is turned counter-clock wise until it stops, the damping is in the soft- est position (position #1). T urn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adju stments. Rear Shock Setting Compression Damping Softest Position #1 F actory Position #4 F[...]

175 Maintenanc e Rear Suspension The rear suspension spring preload, shock rebound damping and shock comp ression damping may be adjusted to suit different ri ding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the vehicle off the ground to allo w the suspension to fully extend. 2. T u rn the adjusting ring c[...]

176 Maintenance Rear Suspension Compression Damping The compre ssion damping clickers are lo cated on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. T o set the shock at the soft est setting (position #1) turn the screw counter-clockwise until it stops. From this position, turn the screw clockwise to increase[...]

177 Maintenanc e Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. CA UTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will [...]

178 Maintenance Cleaning W ashing the V ehicle The best and safest way to clean your Polaris ve hicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing cloth, cleani ng the upper body first and the lower parts last. 2. Rinse with clean water frequently . 3. Dry surfa ces with a chamois to prev ent water sp[...]

179 Maintenanc e Cleaning W ashing the V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage compo nents and could remove paint an d decals. A void directing the water stream at the following items: • Wheel bearings • Electrical components and wiring • T ra nsmission se[...]

180 Maintenance Pol i s hi n g Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Fo llow the instructions on the container . Polishing Tips • A void the use of automotive products, some of which can scratch the finish of your v ehi- cle. • Always use clean cloths and pads f[...]

181 Maintenanc e Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 177. Battery Storage Refer to pages 145-150 for ba ttery storage and battery charging pro cedures. CA UTION Starting the engi ne during the storage period will di sturb the p rotective fil m created by fogging and damage could occur . Never start[...]

182 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 1 10. Air Filter / Air Box Inspect and clean (or replace) the air filter . Clean the air box. Drai n the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as reco mmended in the Period ic Maintenance Chart beginning on pa ge 97. • T r[...]

183 Maintenanc e Storage Stabilize the F uel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel S tabilizer . Follow the instruc- tions on the container for t he recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and[...]

184 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on pa ge 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable supports under the fra me, raise the vehicle sligh[...]

185 Maintenanc e T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in first gear . 3. Lock the parking brake. 4. Remove the key to preven t loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. T u rn the fuel valve off. 7. Always tie the frame of the A TV t[...]

186 Specifications Outlaw 525 IRS Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45 Dry Weight 395 lbs./179 kg Main Jet 148 F uel Capacity 3.9 gal./14.8 l Needle Jet OBDVS Overall Length 71.5 in./182 cm Needle Clip #4 Overall Width 47.5 in./121 cm Slow Air Jet 100 Overall Height 45 in./114 cm Alternator Output 200 w @ 3000 RPM Wheelbase 51 in./130[...]

187 Specifications Jetting Chart Outlaw 525 IRS Driving System T ype Rear T wo- Wheel Drive Tire Size - Front 21 x 7R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 20 x 10R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Br ake Hydraulic Disc, Dual Bore Gear Ratio - 2nd 1.941 Rear Brake Hydraulic Disc Gear[...]

188 P olaris Products P art Number Desc ription Engine Lubr icant 2876244 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (gal.) Grease / Specia lized Lubricants 2871312 Grease Gun Kit, Pre mium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium [...]

189 P olaris Products P art Number Descr iption 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 Bra ke Fluid (12 oz.) 2876335 Hydraulic C lutch Oil (qt.)[...]

190 T roubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine T urns Over , F ails to Start Possible Caus e Solution Out of fuel T urn the fuel valve to reserve, ref uel W ater is present in carburetor or fuel supply Cle an carburetor and/or drai n fuel system and refuel Fuel valve is tu[...]

191 T r oubleshooting Engine T urns Over , F ails to Start Possible Caus e Solution No spark to spark plug Inspect, clean and/or replace spark plugs See your Polaris dealer Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart. If engine f ails to start, i n spect, clean and/or replace spark plugs. Low battery volt[...]

192 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Cause Solution Fuseable link See Polari s dealer for replacement Low battery voltage Rechar ge battery to 12.8 VDC Loose battery connections Chec k all connections an d tighten Loose solenoid connections Chec k all connections an d tighten Possible Cause Solution Poor [...]

193 T r oubleshooting Engine Backfires Possible Cause Solution W eak, fouled or defective spark plug In spect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel R eplace with new fuel Exhaust leak Inspect system for leaks; see your Polaris dealer Incorrectly install[...]

194 T roubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspec t, clean and/or replace spark plug W orn or defective spark pl ug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connect ions Check all connections and t[...]

195 T r oubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Cause Solution Clogged air filter Inspect and clean or replace Electronic throttle control ma lfunction See your Polaris dealer Incorrect idle adjustment Adjust id le speed or see your Polaris dealer Clogged idle jet Disassemble ca rburetor and clean the jets Other mechanic[...]

196 T roubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Lean F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean the fuel system Low octane fuel Replace with recommended fuel Old or non-recommended fuel R e place with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting[...]

197 T r oubleshooting Engine F ails to Reach High RPM Engine Uses Excessive Oil Possible Cause Solution W orn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets T ighten jets Faulty ignition timing See your Polaris dealer Possible Cause Solution Bent engine ventilatio n hose Install a new hose Excessive oil in system Chec[...]

198 T roubleshooting Engine Stops or Loses P ower Possible Cause Solution Out of fuel T urn the fuel valve to reserve, ref uel Interrupted fuel supply Clean fuel system and carburetor Clogged, dirty or wet air filter I nspect and clean or replace Electronic throttle control ma lfunction See your Polaris dealer Other mechanical failure See your Pola[...]

199 T r oubleshooting Engine Stops or Loses P ower Possible Cause Solution Kinked or plugged fuel vent line Inspect and replace W ater present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/or replace spark plugs Fouled or defective spark plug Inspec t, clean and/or replace spark plugs W orn or defective spark pl ug wire See y[...]

200 T roubleshooting Engine Overheats Possible Cause Solution Debris lodged in screen Re move and clean the screen Plugged radiator Use a garden hose to flush any debris from the radia- tor fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency . Insufficient coolant Check levels a nd fill as needed; check for [...]

201 T r oubleshooting Engine F ails to Reach F ull Power Possible Cause Solution Interrupted fuel supply Clean fuel system and carburetor Float leak s Replace t he float Clogged, dirty or wet air filter I nspect and clean or replace Faulty exhaust system Check system for damage; see your Polaris dealer V alve gap is too small Adjust valve gap Fault[...]

202 W arranty LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehi cle (A TV) agai nst defe cts in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warra nty cove[...]

203 W arranty WARRANTY COVERAGE AND EXCL U SIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris limi ted warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accident al damage, normal wear and tear, a buse or improper ha ndling. This war- ranty also does not cover any A TV t[...]

204 W arranty WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLU DING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCLAIMS ALL EXPRE SS W ARRANTIES N[...]

205 W arranty HOW TO OBT AIN WARRANTY SERVICE If your A TV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris A TVs. When requesting warranty service you mu st present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). [...]

206 W arranty EXPORTED VEHICLES EXCEP T WHERE SP ECIFICALL Y REQUIRE D BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA TIO N. This policy does not apply to vehicles that have received authorization for export from Po laris Industries. Dea[...]

207 W arranty EXPORTED VEHICLES How to Get Servic e I n the country wh ere your vehi cle was purchase d: W arranty or Service Bulletin repairs must be done by an authorized Polar is dealer . If you move or are traveling within the country where your vehicle was purchased, W a rranty or Service Bulletin repairs may be requested from any authorized P[...]

208 W arranty EXPORTED VEHICLES How to Get Servic e If Purchased From A Private Party: If you purchase a Polaris product from a pr ivate citizen out side of the country in whic h the vehicle was originally purchased, all warranty cove rage will be denied. Notice If your vehicle is registered outside of the country wher e it was purchased, and you h[...]

209 W arranty U.S.A. EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polar is standard limite d warranty for this vehicle. Polaris warrants that this vehicle is ; (1 ) designed, built, and equipped to conf orm at the time of initial sa le with th[...]

210 W arranty U.S.A. EP A Emissions Limited W arranty The exclusive remedy for bre ach of this limited warranty shall be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products. THE REMEDIES SET FOR TH IN THIS LIM- ITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF T[...]

211 Maintenance Log Present this section of your 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. DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 3 Hours (Break-in) 15 30 45[...]

212 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 60 90[...]

213 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

214 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

215 Index A Age Restrictions . . . . . . . . . . . . . . 14 Air Filter Systems . . . . . . . . . 122-123 B Battery Charging . . . . . . . . . . . . 148-150 Installation . . . . . . . . . . . . . 147 Maintenance . . . . . . . . . . . . 145 Removal . . . . . . . . . . . . . . . 146 Storage . . . . . . . . . . . . 146, 181 Bleeding the Cooling System [...]

216 INDEX F Fluid Brake . . . . . . . . . . . . . . . . 60-61 Clutch . . . . . . . . . . . . . . . . . . 55 Foot Brake . . . . . . . . . . . . . . . . . . . 58 Foot Brake Fluid Lev el . . . . . . . . . 61 Fuel Filter . . . . . . . . . . . . . . . . . . . . 68 Fuel Stabilizer . . . . . . . . . . . . . . . 183 Fuel System . . . . . . . . . . . . . . [...]

217 INDEX S Safety Decals Age 16 Warning . . . . . . . . . . 10 Discretionary War ning . . . . . 10 General Warnin g . . . . . . . . . . 9 No Passenger Warning . . . . . 11 Sport ATV Warnin g. . . . . . . 10 Tire Pressure/Load Warning 11 Safety Trainin g . . . . . . . . . . . . . . . 15 Severe Use . . . . . . . . . . . . . . . . . . 97 Shift Pedal [...]