Polaris Outlaw 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 cannot locate this card, or if it has been removed, plea se call 1-800-34 2-3764 for assistance. 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 THE W A Y OUT are register ed tra demarks of Pola ris Industries Inc. Copyright 2007 Polaris Sales Inc. All in formation contained within this publication is based on the latest product information at the time of publicat ion. Due to constant improvements in the design an d quality of production components, some minor discrepa[...]

3 We l c o m e Thank you for purcha sing a Polaris vehicle, an d 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 world today . Many years of experience ha ve gone into the eng ineering, design, and developm ent of your Polaris vehi cl e, making it the finest machine we've ever produced . For safe and enj oyable operation o f [...]

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 pe rformance engi ne in your 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 pe rform the recom- mended procedures a t the servi ce int[...]

7 Know Y our V ehicle V ehicle Identification Numbers V ehicle Model Number: __ ________________________________ __________________________________ F rame V ehicle Identification Number ( 1): _________________________________________ _____________ Engine Serial Number (2): _______________________________________________________________ ___ Key Numb[...]

8 Safety Decals W arning decals have been pl aced on the vehicle fo r your protectio n. 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 of f, cont[...]

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 publ ic roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instruction • at speeds too fast for your 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 ma y exceed the performance of other A TVs you may have ridden in the pa st. This category S (Sport) A TV is a hig[...]

11 Safety Decals No P assenger W a rning WARNING NEVER ride as a passenger . P assengers can cause a loss of co ntrol, resulting in SEVERE INJURY or DEA TH. 7172566 Tire Pressure/Load W arning 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) RE[...]

12 Safety Riding Gear Always wear clothing suited to the t ype of 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. Whe never riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face 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 pr ohibited for an yone under 16 years of age. This category S (Sport) A TV is a high performance vehicle intended for of f road use only , for sport-type recreation and for competitive use by operators with advanced skills and s[...]

15 Safety Operator Safety Safety T raining A TV safety training is a top priority for Polaris. When you purchased your 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 symbo ls appear throughou t this manual an d on your v ehicle. Y our safety is involved when thes e words and symbols are used. Become familiar with their meanings before r eading the manual. The safe ty alert symb ol , on your vehicle or in this manual, ale rts you to the potential for injur[...]

17 Safety Operator Safety • Read this manual and all labels carefully . Follow all operating procedures. • Never operate an A TV without proper instruction. T ake a training cour se. Pur- chasers of a new Pola ris A TV and age eli- gible family members are entitled to take the A TV RiderCourse sm . Contact A TV Enrollment Express at (800) 887-2[...]

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

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 exces- 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 weigh t uphill. 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 lar ge obstacles, such as rocks or fallen trees. Alway[...]

22 Safety Operator Safety • Always check for obstacles or people behind the A TV before operatin g 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 im[...]

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 co nsumers do not inst all on a Polaris A TV any equipment that may increase the spe ed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any[...]

24 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating this A T V without proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the A TV properly in different situati ons and on different types of terrain. HOW TO A VOID THE HAZAR D Beginning and inexperi enced oper [...]

25 Safety Operator Safety WA R N I N G POTENTIAL HAZARD F ailure to fo llow the skill and experience recommendation s for this A TV . WHA T CAN HAPPEN Severe injury and/or death could occur if a begi n ner or inexperienced driver operates this A TV . HOW TO A VOID THE HAZAR D Only operators with advanced sk ills and su bstantial experien ce sh ould[...]

26 Safety Operator Safety WA R 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 o perates this A TV . Even though a child may be within the recommended age group for operating some A TVs, he/she may not have t[...]

27 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Carrying a pa ssenger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control th e A TV , which could cause an accident and injury to the operator and/or passenger . HOW TO A VOID THE HAZAR D Never carry a passenger . The pu rpose o[...]

28 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating an A TV on paved surfaces, incl uding sidewalks, paths, parking lots, and driveways. WHA T CAN HAPPEN A TV ti res are designed for off- road use. Operating on paved surfaces may adversely affect th e handling of the A TV and could result in loss of control, accident, and/or injury . [...]

29 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highwa ys. WHA T CAN HAPPEN The A TV could collide with another vehicle. HOW TO A VOID THE HAZAR D Never operate the A TV on any public street, road or highway , inclu ding dirt and gravel roads. In many states it's illegal to operate A TVs [...]

30 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating this A TV witho ut wearing an a pproved helmet, eye protection and protective clothing. WHA T CAN HAPPEN Operating an A TV without an ap proved helmet increases the risk of a severe head injury or death in the event of an accident. Operating with out eye prot ection coul d result in [...]

31 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating the A T V after consuming alcohol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drug s could seriously affect operator judgment. Reaction time may be slower and operator balance and perception co uld be affected. Consuming alcohol an d/or drugs before or while operati ng a[...]

32 Safety Operator Safety W ARNING POTENTIAL HAZARD Operating the A T V at excessive speeds. WHA T CAN HAPPEN Excessive speed increases the operator's chance of losing con trol of the A T V , which can result in an accident causing severe inju ry or death. HOW TO A VOID THE HAZAR D Always operate the A T V at a speed that's proper for the[...]

33 Safety Operator Safety WA R 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 HAZAR D Never attempt jumps or other stunts. Avoid exhibiti on driving.[...]

34 Safety Operator Safety WA R N I N G POTENTIAL HAZARD T owing or pulling an object behi nd the A TV . WHA T CAN HAPPEN A wagon, sled or other object tow ed behind an A TV does not ha ve brakes or stee ring. The o bject may overturn or collide with other objects and ca use serious injuries. HOW TO A VOID THE HAZAR D Never tow or pull an object beh[...]

35 Safety Operator Safety WA R N I N G POTENTIAL HAZARD F ailure to use extra caution when operating the A TV on unfamiliar terrain. WHA T CAN HAPPEN Unfamiliar terrain may contain hidden rocks, b umps, or holes that could cause loss of control or ov erturn. HOW TO A VOID THE HAZAR D T ravel slowly and use extra caution when operatin g on unfamilia[...]

36 Safety Operator Safety WA R N I N G POTENTIAL HAZARD F ailure to use extra caution when operati ng on excessively rough, slippe ry or loose terrain. WHA T CAN HAPPEN Operating on excessively ro ugh, slippery or loose terrain could cause loss of traction or loss of control, which could result i n an accident or overturn. HOW TO A VOID THE HAZAR D[...]

37 Safety Operator Safety W ARNING POTENTIAL HAZARD T urning improperl y . WHA T CAN HAPPEN Improper turns co uld cause loss of control and lead to a collision or overturn. HOW TO A VOID THE HAZAR D Always follow proper procedures fo r turning as described in the owner's manua l. Practice turning at slow speeds before attempting to turn at fas[...]

38 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during op eration. 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 pl anted on t he foot[...]

39 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating on e xcessively ste ep hills. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZAR D 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 WA R 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 HAZAR D Always follow proper procedures fo r climbing hills as described in the Owner's Manual beginn ing on page 82. Always check the terrain carefull y before a[...]

41 Safety Operator Safety WA R N I N G POTENTIAL HAZARD T raveling downhill imprope rly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZAR D Always follow proper procedures fo r traveling down hills as described in the owner's manual. NOTE: A special technique is required when braki[...]

42 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHA T CAN HAPPEN Improperly crossing or turning as hills cou ld cause loss 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 turn ing technique (on level ground) as descri[...]

43 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Stalling, rolling backwards or improp erly dismounting whil e climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZAR D Maintain steady speed when climbi ng a hill If all forward speed is lost: Keep your weight uphill. Apply the front brakes gradually (right le ve[...]

44 Safety Operator Safety W ARNING POTENTIAL HAZARD Skidding or sliding. WHA T CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedl y , the A TV could overturn. HOW TO A VOID THE HAZAR D On slippery surfa ces such as ice , travel sl owly and use extra caution to reduce the chance of skidding or sliding [...]

45 Safety Operator Safety W ARNING POTENTIAL HAZARD Operating on frozen bodies of water . WHA T CAN HAPPEN Severe injury or death can result if the A TV and/or the operator fall thro ugh the ice. HOW TO A VOID THE HAZAR D Never operate the A TV on a frozen body of water . WA R N I N G POTENTIAL HAZARD Operating this A TV with improp er tires, or wi[...]

46 Safety Operator Safety WA R N I N G POTENTIAL HAZARD Operating the A T V through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of co ntrol, which could lead to an accident or overturn. HOW TO A VOID THE HAZAR D Avoid operating the A T V through deep or fast-flowing water . If it's unavoidab[...]

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

48 Safety Operator Safety W ARNING Safe operation of this rider -active vehicle requires good j udgement and physical ski lls. P ersons with cogni tive or physical disa bilities who operate this vehicle have an increased risk of overturn and loss of control, which could result i n severe inju ry or death. WA R N I N G Operating a damaged A TV can r[...]

49 Safety Operator Safety W ARNING 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 traveli ng through tall grass, especially dry grass. WA R N I N G[...]

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 when the engine starts. NOTE: If the starte r fails to engage, replace the blown fuse or see your P[...]

52 F eatures and Controls Lights Indicator Lights An illuminated light in the indicator window will alert you to the follow- ing condition s. • Hot en gine • 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- ag[...]

53 F eatures and Controls Lights Headlights Use the light switch to t urn the lights on and of f and to switch the lights from high beam to low beam. NOTE: The ligh ts won't work unless the key is in the ON position and the engine stop switch is in the RUN position. WA R N I N G Operating the A TV on streets or roads, especially in darkne ss, [...]

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 dis engage the clutch. Disengage the clutch before shifting ge ars. The clutch is self-adjusting, but lever position can be changed to fit the operato r ’ s hand. T urn the adjusting knob counterclo[...]

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 vehicle movem ent. 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. WA R N I N G The Electronic Throttle Control (E[...]

58 F eatures and Controls F oot 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 brak e fluid leve l frequently for the foot brake system. The reservoir is loc[...]

59 F eatures and Controls Hand Brake The hand brake operates the front brakes. The hand brake is loc ated on the right handl ebar . 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 s[...]

60 F eatures and Controls Master Cylinder/Brake Fluid Under normal operation, the diaphragm 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 dia phragm should be replaced. Always fill the r eservoir as needed whenever the cover is loosened or removed to ensure pr[...]

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 th e fluid level, the master cylinde r cover must be level. Hand Brake Fluid Leve[...]

62 F eatures and Controls Pa r k i n g B r a k e 1. Place the transmission in fi rst 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 parking brake lock, squeeze and release the brake lever . The lock will aut[...]

63 F eatures and Controls Pa r k i n g B r a k e Important Safeguards • The parking brake may relax i f left on for a long period of time. Always 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 dep[...]

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 boot und[...]

65 F eatures and Controls Manual Shift Shifting Gears NOTE: Always allow a cold engin e to warm up before sh ifting gears. 1. When starting from a stopp ed position, place the trans mission in neutral. 2. Squeeze and hold the brake lever . NOTE: Do not squeeze the th rottle lever . 3. Squeeze the clutch leve r to disengage the clutch. 4. Depress th[...]

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 fi rst gear . See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmi ssion. 3. Shift down into reverse gear . NOTE: The lock wi[...]

67 F eatures and Controls Manual Shift Deceleration T o slow or stop the ve hicle, release the thro ttle lever and apply the bra kes smoothly and evenly . As the vehicle slows and engine RPM de creases, disengage the c lutch and shift to a lower gear . NOTE: Be sure the engine RPM has sufficiently decrea sed before shifting to a lower gear . WA R 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 alve 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 su pply is exhausted. NOTE: There's abou t a 5 to 8 mile (8 to 13 km) range on reserve gas. Alwa ys refill the ga s tan[...]

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. Th e break-in period for your n ew Polaris A TV is the first three hours of operation, or the time it takes to use 5-6 ga llons (20 lit ers) of fuel . Do not allow engine speed to exceed 7000 RPM during the bre[...]

71 Break-In P eriod 1. Fill the fuel tank with gasoline. See page 74. 2. Check the oi l level. Add the recommended oil as needed to maintain the oil level in the proper range. See pa ge 109. 3. Allow the engine suf ficient time to warm up before operating. 4. Drive slowly at first. Select an open area t hat allows room to familiarize yourself wi th[...]

72 Pre-Ride Inspection WA R N I N G If a proper inspection is not done before ea ch us e, severe injury or dea th could result. Always inspect the vehicl e before each use to ensu re it's in proper operating condi tion. Pre-Ride Check list P age Brake systems / lever travel En sure proper operation 58-63 160-161 Brake fluid Ensure p roper leve[...]

73 Pre-Ride Inspection Pre-Ride Check list P age Coolant (if applicab le) Ensure proper level 119 Coolant hoses (if ap plicable) Inspect for leaks -- Throttle Ensure smooth operation 56 Indicator lights / switches Ensure operation 52, 53 Engine stop switch Ensure proper ope ration 51 Air filter Inspect, clean, replace as needed 122 Air box sediment[...]

74 Operation F uel System WA R N I N G Gasoline is highly flammable and explosive under certain con ditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and ou tdoors 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 sta rted 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: F uel is injected into the intake passage each time the throttle lever is depressed. Do no t depress the throttle leve r while starting the en gine. Do [...]

76 Operation Starting the Engine 1. Shift the transmission to neutral. 2. Lock th e parking b rake. 3. T urn 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 engine stop switch to the RUN position. 8. T urn[...]

77 Operation Starting the Engine NOTE: If starting the e ngine while in gear , a pply the ha nd brake and squeeze the clutch lever ful ly to disengage the clutch. If starting the engine wh il e in neutral, the neutral indicator light 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 th e handleb ars. 2. S tart the engine and allow it to warm up. 3. Shift the transmission into gear . See page 64. 4. Check you r surroundings and determi ne your path of travel. 5. Release the parking brake. 6. Slowly depress the throttle with your ri gh[...]

79 Operation Making T urns Practice making turns at s low 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 sli g[...]

80 Operation Driving on Slippery Surfaces WA R N I N G F ailure to exercise care whe n operating on slippery su rfaces can result in loss of tire traction and cause loss of control, acciden t, and serious injury or dea th. Never apply the brakes during a skid. Do not operate on excessi vely slippery surfaces. Always reduce speed and use add itional[...]

81 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these prec autions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by tu[...]

82 Operation Driving Uphill WA R N I N G Braking and handling are greatly affe cted when oper ating in hilly terrain. Improper proce dure could cause loss of control or overturn and result in seri ous injury or death. Avoid climbing steep hills (25 ° ma ximu m). Use extreme caution when operatin g on hills, and follow proper ope rating pro cedures[...]

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 footp egs. 4. T ransfer your weight forward. 5. Proc eed at a steady rate of sp eed and throttle opening. 6. Remain alert and b e prepared t o take emergency action. This [...]

84 Operation Driving Across Hillsides WA R N I N G Improperly crossing hills or turning on hills can resu lt 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 foo tpegs. 3. S teer slightly into the hill to maintain direction. NOTE: If the vehicle begins to tip, quick[...]

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 acros s the handlebar an d apply the front brakes to unlock 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 brakes [...]

88 Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. T ransfer 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. WA R N I N G Excessive speed ca n cause loss of co[...]

89 Operation P arking on a Hill or Incline A void parking on a hi ll or incline i f pos- sible. If it's unavoidable, follow these precautions: 1. T urn th e engine off. 2. Place the transmission in first gear . 3. Lock th e parking b rake. 4. Always block the rear wheels o n the downhill side. See illustration. 5. T urn the fuel valve off.[...]

90 Operation Driving Through W a ter Y our A TV can operate th rough water with a maximum recommended depth equal 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 gradua l inclines. 3. Proceed slowly , avoiding rock[...]

91 Operation Driving Through W a ter A void operating your A TV through deep or fast flowing water . If the A TV is op erated in deeper wate r than reco mmended, it's critical to have it servic ed as outli ned in the mainte- nance chart beginning on page 97. Engine oil and all grease f ittings need speci al attention. NOTE: Avoid opera ting th[...]

92 Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the brakes lightly for stopping. 3. A void turning at sharp angles. 4. Always avoid ba cking downhi ll. 5. Never open the throttle suddenly while backing. 6. Always look left, right and be hind 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. WA R N I N G F ai lure to use ca ution when operating in reverse can re sult in seri ous injury or de ath. Before shifting into reverse, always check for obstacles or p[...]

94 Operation Driving Over Obstacles Be alert! Look ahead an d learn to read th e ter- rain you're traveling on . Be constantly alert for hazards such as logs, rocks and low hang- ing branches. W ARNING Severe injury or death ca n result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visi ble. T ravel[...]

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

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 Maintena nce P eriodic Maintenance Chart The high pe rformance eng ine in you r 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 [...]

98 Maintenance P eriodic 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 Maintenance Log beginning on page 21 1. NOTE: Service and adjustmen ts are crit ica[...]

99 Maintena nce P eriodic Maintenance Chart Maintenance Chart Ke y 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 af fect emissions.) Q Have an authorized Polaris dealer perform these services. z Use Polaris Premium All Season Gre[...]

100 Maintenance P eriodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used Brake systems/br ake fluid -- Pre-ride -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist. 72 Tires -- - - Wheels/lug nuts -- -- F rame fasteners -- -- Coolant[...]

101 Maintena nce P eriodic 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallo[...]

102 Maintenance P eriodic Maintenance Chart Item Maintenanc e Interval (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 -- Inspec[...]

103 Maintena nce P eriodic 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallo[...]

104 Maintenance P eriodic Maintenance Chart Item Maintenanc e Interval (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 T V/driving in water X z F ront A-Arms (2) 45 6 M -- Inspect; tigh ten fasteners; grease (also after washing A [...]

105 Maintena nce P eriodic 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallo[...]

106 Maintenance P eriodic Maintenance Chart Item Maintenanc e Interval (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 a nd replace if at or below service limit E Oil scraper ring 90 -- 156 (600) Camshaft 90 -- 15[...]

107 Maintena nce P eriodic 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallo[...]

108 Maintenance Engine Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Peri odic Maintenance Chart beginning on page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a similar oil desi gne d for use in 4-stroke manual clutch A TV and motorcyc le application[...]

109 Maintena nce 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 cause en gine overheating, which could result in en gine dama[...]

110 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginni ng on page 97. Perform the initial break-in oil change after the fi rst three hours of operatio n. Always change both oil filters and clea n the oil screens whenever changing oil. NOTE: Change the oil mo re frequently on vehic[...]

111 Maintena nce Engine Oil Change 1. Position the vehicle on a level surface. NOTE: Remove the skid plate fo r better access to the oil drain p lug and short scree n. 2. S tart the engine. Al low it to idle for two to three minutes. S top the engi ne. 3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain complet[...]

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 Maintena nce 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 Lo ng Oil Screen 1. Remove the long screen p lug, located on the side of the engine near the engine number . 2. Remove the oil scree n. Clean the screen thoroughly and blow wi th compressed air . 3. Check the O-rings. If d amaged, install new O-rings. 4. Place the long oil screen on a pin-type key or s[...]

115 Maintena nce Engine Oil Change Cleaning the Lo ng Oil Screen 5. Insert the tool thro ugh the op ening and into the bore of the opposite en gine 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 po[...]

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 covers. 3. Using circle clip (sna p ring) pli ers, 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 Maintena nce 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. S tart the engine. All ow it to idle for at le[...]

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 Maintena nce Engine Cooling System Coolant Level The recovery bottle is locat ed on the right side of the vehicle under the fron t fender . The fluid leve l must be maintained be tween the FULL and ADD marks on the side panel (when the fluid is co ol). As coolant operating te mperature increases , the expanding (heated) excess co olant is force[...]

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 pressure ca p. 2. Using a funnel, slowly add coolant as necessary through the radiator filler neck. 3[...]

121 Maintena nce Engine Cooling System Cooling System Bleeding Bleeding the cooling system is required o nly if the system 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 pressure ca p. 2. Using a funnel, slowly add th e recommended coolant. Fil[...]

122 Maintenance Air Filter Systems NOTE: Refer to the illu strations on 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 foa[...]

123 Maintena nce Air Filter Systems Step 3 Step 5 Step 4 Step 7 Step 6[...]

124 Maintenance Carburetor Normal wear from engine vib rations 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 Maintena nce Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be g inning on page 97. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. T urn the fuel valve off. 2. Place a suitable container under the carburetor to[...]

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, certai n adjust- ments can be made to improve its operation an d driveability . Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly [...]

127 Maintena nce Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from you r skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WA R N I N G P oor lighting while driving can result in severe in jury or death. Head light and taillight lenses become dirty during normal operati on. W[...]

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. S tart the engine and turn th e headlight switc h to high beam. 4. Observ[...]

129 Maintena nce 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 (se e page 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the lar ge pivot bracket and remove the headlamp. 5. Install the new headlamp by inserting the outboard pivot pin in the [...]

131 Maintena nce Lights Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboa rd pivot pin of the headlamp. Adjust for approximately 1/16" clearance betwe en 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 free[...]

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

133 Maintena nce F ront Cab Re moval 1. Remove the left and righ t cab mount screws (1 ). 2. Remove the wire harness connector from the cab. The conn ector is lo cated 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-of f. Place [...]

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 side panel. Side Pa n e l Screw[...]

135 Maintena nce Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove the cab. 1 3 2[...]

136 Maintenance Spark Plugs Refer to the specifications section beginning on page 186 for recommended spark plug type and gap. Spark plug condition is indicativ e of engine operat ion. The spark plug firing end condition should be read after the engine has been warmed up an d the vehicle has been drive n at higher speeds. Immediately check the spar[...]

137 Maintena nce 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 insulato r ti p indicates overheating, caused by use [...]

138 Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right s ide 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 Maintena nce Spark Arrestor Clean-Out T o remove accumulated carbon, clean the spa rk arrestor at the interv als recommended in the Periodic Maintenance Char t beginni ng on page 9 7. WA R N I N G F ai lure to heed the fo llowing warnings whil e servicing the spark arrestor could result in serious injury or death. Do not perform clean-out immed[...]

140 Maintenance Spark Arrestor Clean-Out NOTE: Refer to the illu stration on page 141. 1. Remove the retaining screw and remove the arrestor from the end of the muf fler . 2. Use a no n-synthetic brush to clean the arr estor screen. A synthetic brush may melt if components are warm. NOTE: If necessary , blow debris from the screen with comp ressed [...]

141 Maintena nce 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 follo wing procedures if you don't feel completely capable, or if you sus- pect that water has entered the fuel tank (lik e[...]

143 Maintena nce V ehicle Immersion 1. T urn 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 spark pl ug. 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 tim[...]

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 Maintena nce Battery The seal ed battery is already fi lled with el ectr olyte and has been sealed and fully char ged at the factory . Never pry the sealing strip of f or ad d any other flu id to this battery . Keep the battery terminals and connections free of corrosion. If c leaning is necessary , remove the corrosion with a stif f wire brush[...]

146 Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Battery Removal 1. Remo[...]

147 Maintena nce Battery Installation NOTE: Always install a fu lly charged battery . Using a n ew battery that has n ot been fully charged ca n damage the battery and result in a shorter li fe. It can also hinder vehicle performan ce. If recharging is necessary , use a .5 amp battery charger . 1. Place the battery in the ba ttery holder . 2. Conne[...]

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 wil l register 12.8 V or high er . If the voltage is less than 12.8 volts, recharge the battery . The battery may be rechar ged without removing it from the vehicl[...]

149 Maintena nce 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 u sing a constant curren t char ger , use the guidelines on the following page for rechar ging. WA R N I N G An overheated battery could explode, causin g seve[...]

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 months from date of manufacture None required 75%-100%[...]

151 Maintena nce Tires Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. WA R N I N G Operating your A TV with worn ti res, improperly inflated tires, non-stand ard tires or impro perly installed tires will affect vehicle handli ng and could cause an accident resulting in seriou s injury or death. Maintain[...]

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 performe d by your authorize d Polaris dealer . Wheel Removal 1. S top[...]

153 Maintena nce Wheel Installation 1. Place the transmission in gear . Lock the pa rking 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 veh icle to the grou nd. 5. Securely tighten the[...]

154 Maintenance Boot Inspection Before Operating Inspect the b oots before op erating the veh icle. 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 balloo ned, perform the boot b urping procedure on page 155. Go[...]

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

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

157 Maintena nce Clutch System Bleeding 4. Remove the bleeder screw (2) from the slave cylinde r . 5. Press fluid into the system unti l the fluid runs out of the hole (3) in the master cylinder without producing bubbles. NOTE: Extract fluid from th e master cylinde r during the pr ocess to prev ent overfl owing. 6. When finished, remove the bleede[...]

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 Maintena nce 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 freeplay , be sure to flip the throt[...]

160 Maintenance Brakes Both brakes are self-adjusting, but the following checks are re commended to keep the brake systems in good operating condition. Check more often if brakes are used he avily under nor- mal operation. WA R 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 Maintena nce 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 loosenes s. 5. Check the security and su rface condition of the disc. 6. Inspect the rear brake disc s[...]

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-a head po sition. Use tie straps to secure the handlebars to the rear grab bar so they can't move. 3. Place s[...]

163 Maintena nce T oe Alignment 4. T ie an elastic string around the sta nds, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front 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 two[...]

164 Maintenance Chain T ension Check the amount o f chain slack by mo ving 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 t he following page if the chai n needs adjus tment. NOTE: The chain has [...]

165 Maintena nce Chain T ension 1. Loosen the upper and lowe r pivot mounting bolts (1). 2. Threa d the chain ad jus ting bolt (2) inward or outward to adjus t chain slack to the proper dimension. 3. T ighten the piv ot 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 ope[...]

166 Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Loosen the four hand lebar bolts. 2. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other pa rt of the machine when turned fully to the left or right. 3. T orque the two front bolts to 10-12 ft. lbs. (1[...]

167 Maintena nce Steering Inspection Check the steering assembly periodic ally for loos e nuts and bolts. If loose nuts a nd bolts are found, or if you notice any freeplay in the stee ring post, see your Polaris dealer for service before operating the vehi cle. 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 fron t of the vehicle by placing a suitable stand under the frame. NOTE: The tires sh ould be barel y touching the ground and the suspension sho uld be at full rebound. 4. Measure the distance from the ground to the b[...]

169 Maintena nce 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 pushing down on the suspension . 7. T urn th e handlebars fully to the left and right. 8. W ith the rider still on the vehicle, repeat the me asuremen t 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. WA R N I N G Uneven adjustment may ca use poor handling of th e A TV , which could result in an acciden t and serious injury or death. Always adjust both the le ft and right spring preloads equally [...]

171 Maintena nce 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 urn th e adjusting ring clockwise to inc rease preload (1). T urn the ring counter-clockwise to decrease preload (2). 4. T ighten the jam nut against the adjusting[...]

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 tire s should be barely touching the ground and the suspension sho uld be at full rebound. 4. Measure the distance from the ground to the botto[...]

173 Maintena nce Rear Suspension Suspension Set-Up 5. Remove the stand and have a r ider sit comfor tably on the seat with han ds 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 pushing down on the suspension . 7. T urn th e 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 adjustments. Rear Shock Setting Compression Damping Softest Position #1 F actory P osition #4 F[...]

175 Maintena nce Rear Suspension The rear suspension spring preload, shock rebound damping and sh ock compression damping may b e adjusted to suit dif ferent riding 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 urn th e adjusting ring [...]

176 Maintenance Rear Suspension Compression Damping The comp ression d amping cli ckers 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 incre[...]

177 Maintena nce 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 componen ts. P olaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, includin g insect repellents and chemicals, wi[...]

178 Maintenance Cleaning W ashing the V ehicle The best and safe st 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 frequ ently . 3. Dry su rfaces with a cham ois to preve nt water[...]

179 Maintena nce Cleaning W ashing the V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may d amage components and could remove paint and d ecals. A void directing the water stream at the following items: • Wheel bearin gs • Electrical components and wiring • T ransmission se[...]

180 Maintenance Po li s h i ng Polaris recommends the use of common household aerosol furniture polish for polishi ng the finish on your Polaris vehicle. Fo llow the instructions on the container . Polishing Tips • A void the use of automotive products, so me of which can scratch the finish of you r vehi- cle. • Always use clean cloths an d pad[...]

181 Maintena nce Storage Exterior Make necessary repairs and c lean the vehicle as recommended. See page 177. Battery Storage Refer to pages 145-150 for battery storage and battery char ging procedures. CA UTION Starting th e engine during the stora ge period will di sturb the pr otective film created by fogging and damage could o ccur . Neve r sta[...]

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 o n page 97. • T r[...]

183 Maintena nce Storage Stabilize the F uel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fu el T reatmen t or Polaris Fuel S tabilizer . Follow the instruc- tions on the contain er for the recommended amou nt. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves[...]

184 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recomme nded in the Periodic Main- tenance Chart beginning o n page 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable su pports unde r the frame, raise the vehicle sli[...]

185 Maintena nce 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 th e parking b rake. 4. Remove the key to prev en t loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. T urn the fuel valve off. 7. Always tie the frame of the A TV[...]

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 Dr ive 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 Gea[...]

188 P olaris Products P art Number Description Engine L ubricant 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 / Spec ialized Lubrican ts 2871312 Grease Gu n Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grea se (3 oz. cartridge) 2871423 Premi[...]

189 P olaris Products P art Number Description Coolant 2871323 60/40 Coo lant (gal.) 2871534 60/40 Coo lant (qt.) Additives / Miscellaneo us 2871326 Carbon Clean Plus (12 o z.) 2870652 F uel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid (12 oz.) 2876335 Hydraul ic Clutch 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 Pos sible Cause Solution Out of fuel T urn the fuel valve to reserve, refuel W ater is present in carburetor or fuel supply Cle an carburetor and/or drai n fuel system and refuel Fuel valve is tur[...]

191 T roubleshooting Engine T urns Over , F ails to Start Pos sible Cause 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, in spect, clean and/or replace spark plugs. Low battery voltag[...]

192 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Caus e Solution Fuseable link See Pol aris dealer for replac ement Low battery voltage Rechar ge battery to 12.8 VDC Loose battery connections Chec k all connectio ns and tighten Loose solenoid connections Chec k all connectio ns and tighten Possible Caus e Solution Po[...]

193 T roubleshooting Engine Backfires Possible Caus e Solution W eak, fouled or def ective 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 Replace 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 Caus e 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 an d[...]

195 T roubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Caus e 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 Le an F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, cl ean the fuel system Low octane fuel Replace with recommende d fuel Old or non-recommended fuel Re place with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetti[...]

197 T roubleshooting Engine F ails to Reach High RPM Engine Uses Excessive Oil Possible Caus e Solution W orn or dirty needle valve Clean and/or replace need le valve Loose carburetor jets T i ghten jets Faulty ignition timing See your Polaris dealer Possible Caus e Solution Bent engine ventilatio n hose Install a new hose Excessive oil in syste m [...]

198 T roubleshooting Engine Stops or Loses P ower Possible Caus e Solution Out of fuel T urn the fuel valve to reserve, refuel 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 roubleshooting Engine Stops or Loses P ower Possible Caus e Solution Kinked or plugged fuel vent line Inspect and replace W ater prese nt in fuel Replace with new fuel Overuse of choke Ins pect, cl ean 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 [...]

200 T roubleshooting Engine Overheats Possible Caus e 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 ef ficiency . Insufficient coolant Check levels a nd fill as needed; check fo[...]

201 T roubleshooting Engine F ails to Reach F ull P ower Possible Caus e Solution Interrupted fuel supply Clean fuel system and carburetor Float leak s Replace the flo at 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 Faul[...]

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 t he Polaris All T errai n V ehicle (A TV) agai nst defects in ma terial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warra nty cov[...]

203 W arranty W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris l imited warranty e xcludes any failures t hat 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. Th is war- ranty also does not cover any A T[...]

204 W arranty W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLUDING 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 EXPRESS W ARRANTIES NO[...]

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 SPECIFICAL L 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 LO CA TION. 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 Ser vice I n the countr y where yo ur vehicle was purcha sed: W arranty or Service Bulletin repairs must be done by an auth orized 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 [...]

208 W arranty EXPORTED VEHICLES How to Get Ser vice If Purchased From A Priv ate Party: If you purchase a Polaris product from a pr ivate citizen out side of the country in whic h the vehicle was o riginally 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[...]

209 W arranty U.S.A . EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Uti lity V ehicle (ORUV) emissions limited warranty is in additi on to the Po laris standard limite d warranty for this vehicle. Polaris warrants that this vehicl e is; (1 ) designed, built, and equipped to conf orm at the time of initia l sale with[...]

210 W arranty U.S.A . EP A Emissions Limited W arranty The exclusive rem edy for breach of this limited warranty sha ll be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products. THE REMEDIES SET FOR T H IN THIS LIM- ITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH [...]

211 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced . This will p rovide 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 Flui d Level . . . . . . . . . 61 Fuel Filter . . . . . . . . . . . . . . . . . . . . 68 Fuel Stabilizer . . . . . . . . . . . . . . . 183 Fuel System . . . . . . . . . . . . . . [...]

217 INDEX S Safety Decals Age 16 Warn ing . . . . . . . . . . 10 Discretionary Wa rning . . . . . 10 General Warn ing . . . . . . . . . . 9 No Passenger War ning . . . . . 11 Sport ATV W arning . . . . . . . 10 Tire Pressure/Load Warning 11 Safety Tra ining . . . . . . . . . . . . . . . 15 Severe Use . . . . . . . . . . . . . . . . . . 97 Shift Ped[...]