Polaris Outlaw 9922079 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 2008 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 Content s Introduction . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . 10 F eatures and Controls . . . . . . . . 38 Operation . . . . . . . . . . . . . . . . . . 58 Emission Control S ystems . . . . . 86 Maintenance . . . . . . . . . . . . . . . . 85 Specifications . . . . . . . . . . . . . . 168 P[...]

6 Introduction Safety W ords and Symbols 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 safety ale rt symbol indicates a potentia l personal injury hazard. W ARNING A W A[...]

7 Introduction Failure to follow the warning s and safety precautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy an d can be hazardous to opera te. This vehicle handles differently than other vehicles, su ch as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneu[...]

8 Introduction Service Requirement s 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 t[...]

9 Introduction V ehicle Identification Numbers V ehicle Model Number: _____________ _______________________________ ________________________ F rame V ehicle Identification Number ( 1): _________________________________________ _____________ Engine Serial Number (2): __________________________________________ ________________________ Key Number (on [...]

10 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 age eli gible fa[...]

11 Safety Safety T raining A Polaris A TV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Follow the recommen ded maintenanc e program outlined in yo ur owner's manual . This program is designed to ensure that all critical components on your vehicle are thoroughl[...]

12 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 ve hicle, or make any other modifications to the vehicle for these purposes. Any modifications [...]

13 Safety Safe Riding Gear Always wear clothing suited to the t ype of riding. A TV riding requires special protec tive clothing for comfort and to reduce the ch ance of injury . Helmet W earing a helmet can prevent a severe head injury . When- ever riding a Polaris vehicle, always wear a helmet tha t meets or exceeds establishe d safety standards.[...]

14 Safety Safe 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 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 r[...]

15 Safety Safety W arnings Failure to operate the A TV properly can result in a co llision, loss of control, a ccide nt or overturn, which may result in se rious injury or d eath. Heed all sa fe ty warnings outlined in this section of the owner ’ s manual. See the OPERA TION section of the ow ner ’s manual for proper operating procedure s. Oper[...]

16 Safety Safety W arnings Operating Wit hout Instructio n Operating this A TV without proper in struction increases the ri sk of an accident. The opera tor must unde rstand how to operate the A TV properly in different situations and on different types of terrain. Beginning and inexperie nced oper ators shoul d complete the A TV RiderCourse sm off[...]

17 Safety Safety W arnings Handling G asoline Gasoline is h ighly flammable and explosive under certain condi tions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling[...]

18 Safety Safety W arnings Failure to Inspect Before Oper ating Failure to inspect and verify that the A TV is in safe operating conditi on before operating increases the risk of an accident. Always inspect the A T V before ea ch use to make sure it's in safe operating condition. Always fo llow all inspecti on and maintenance procedures and sc[...]

19 Safety Safety W arnings Carrying a Passenger Carrying a passenger greatly reduces the operator's abil ity to bal ance and control the A TV , which may result in an accident or overturn. Never carry a passenger on thi s A TV . Using Alcohol or Drugs Operating the A TV after consuming a lcohol or drugs could adve rsely affect operator j udgme[...]

20 Safety Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (includin g sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result i n loss of control and accident o r overturn. Avoid operating the A TV on p avement. A TV tires are desig ned for of f-road use . If it's [...]

21 Safety Safety W arnings Operating at Excessiv e Sp eeds Operating the A TV at excessive speeds increases the operator's risk of losing contro l. Always operate at a speed that' s appropriate for the terrain, the visibility and operati ng conditions, and your expe rience. Physical Control of the A TV Removing a hand from the hand lebars[...]

22 Safety Safety W arnings T urning Improperly T urning improperly could cause l oss of tracti on, loss of control, accid ent or overturn. Alw ays follow proper procedures for turning as describ ed in the owner's manual. Never turn abruptly or at sharp ang les. Never turn at high speeds. Practice tu rning at slow speeds before attempting to tu[...]

23 Safety Safety W arnings Improper Hill Clim bing Improper hill climbing c ould cause loss of control or overturn. Always follow prop er procedures for climbing hills a s described in the owner' s manual. See page 72. Operating on S teep Hills Operating on excessivel y steep hill s could cause an overturn. Never operate on hil ls too steep fo[...]

24 Safety Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures fo r traveling down hills as described in the owner's manual. NOTE: A special tech- nique is require d when braking whil e traveling down hill. See pa ge 75. • Always descend a hill [...]

25 Safety Safety W arnings Crossing Hillsides Driving on a sidehill is not recommended. Imprope r procedure could cause loss of control or overtu rn. Avoid crossing the side of any hill unless absolutely nece ssary . If crossing a hillside is unavoid able, always follow proper procedures as described in the owne r's manual. See page 74. Never [...]

26 Safety Safety W arnings S t alling While Climbing a Hill S talling, rolling backwards or improp erly dismounting while climbing a hill could cau se an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost Keep body weight uphill. Apply the front brakes graduall y (right lever). When fully stopped, apply th e[...]

27 Safety Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, slippery or loose terrain could cause loss of tracti on, loss of control, accid ent or overturn. Do not operate on excessively rough, slippe ry or loose terrain until you've learned and practiced the skills necessary to [...]

28 Safety Safety W arnings Operating in Unfamiliar T errain Failure to use extra caution when ope rating on unfamiliar terrain coul d result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. T ravel slowly and use extra caution when operating on unfamil iar terrain[...]

29 Safety Safety W arnings Improper V ehicle Modifications Improper installation of accessories or modification of the A TV may cause changes in handling, which co uld caus e loss of control or a n accident. Never modify the A TV through impro per installation or use of accessories. All part s and accessories added to the vehicle mu st be genuine P[...]

30 Safety Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating throu gh deep or fa st-flowing wate r . If it's unavoidab le to enter water that exceeds the height of the footpegs: • T ravel slowly . • Balance[...]

31 Safety Safety W arnings Poor Visibility Operating the A TV in darkness or inclement weather coul d result in a collision or accident, especially if operating on a road or street. This A TV is not e quip ped with highway-approv ed lights. Operate thi s vehicle off-road only . Use caution a nd drive at reduced speeds in conditions of reduce d visi[...]

32 Safety Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodies of water ma y result in serious injury or death if the A TV and/or the operator fall through the ice. Never opera te the A TV on a frozen body of water . Operating a Damaged A TV Operating a da maged A TV can result in an accident. After any overturn or accid[...]

33 Safety Safety W arnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause 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. Unauthor[...]

34 Safety Safety Labels and Locations W arning labels have been placed on the vehicle for your protec tion. Read and follow the instructions on each label carefully . If any of the labels shown in this manual dif fer from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic[...]

35 Safety Safety Labels and Locations General W arning W ARNING 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. Neve r carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instruction • at speeds too fast for your s[...]

36 Safety Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if yo u 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. 7175374 Discretionary/Sport A TV W arning W ARNING • Never operate this A TV on HILLS steeper th an 25 degrees 25 ° . T o prevent over[...]

37 Safety Safety Labels and Locations No Passenger W arning W ARNING NEVER ride as a p assenger . Passengers can cause a loss of control, resu lting in SEVERE INJURY or DEA TH. 7175378 Ti re Pressure/Load W arning W ARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold[...]

38 Features and Controls Start Butt on Engin e Stop Switch Main Key Switch[...]

39 Features and Con trols Main Key Switch The main key switch must be in the RUN position to start the engine. See page 66 for starting procedures. Star t B u t to n Press the start button to engage the starter . Alwa ys release the start button promptly when the engine starts. If the starter fails to engage, re place the blown fuse or see your Pol[...]

40 Features and Controls Light s Indicator Light s 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 If indicator lights fail to operate, check connections. See your Polaris dealer for inspection of the capacitor and voltage regulator[...]

41 Features and Con trols Light s Headlight s Use the headlight switch to turn the lights on and of f and to switch the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Headlight Switch[...]

42 Features 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 countercloc[...]

43 Features and Con trols 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 [...]

44 Features and Controls Throttle Lever Operating an A TV with sticking or impr operly operating throttle contro ls could cause an accident. Never start or operate an A TV that has a sticking or impr operly operatin g throttle. Always contact your dealer for service before operating th e vehicle. Failure to check or maintain proper operation of th [...]

45 Features and Con trols Throttle Lever The throttle lever is located on the right handlebar . Squeeze the lever toward the handlebar to increase engine speed and vehicle movement. Fuel is injected into the inta ke passage each time throttle is app lied. Do not squeeze the throt- tle lever while starting the engine. Do not squeeze the throttle lev[...]

46 Features and Controls Foot Brake The foot brake operates the rear brakes. The brake pedal is located in front of the righ t-hand footpeg. If the rear wh eels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding. Check the brak e fluid le vel frequently for the foot brake system. The reservoir is loca[...]

47 Features and Con trols Hand Brake The hand brake operates the front brakes. The hand brake is located on the right ha ndlebar . These brakes are hydraulically activated disc type brakes. Squeeze the brake lever toward the handlebar to engage the front brakes. Always test brake lever travel and master cylinder fluid level before riding. When sque[...]

48 Features and Controls Master Cylinder/Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the reco mmended level. Do not overfill. Never store or use a partial bottle of brake fluid. Br ake fluid is hygrosco pic, meaning it rapidly absorbs moisture from the ai[...]

49 Features and Con trols 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 170 for the part nu mbers of Polaris prod- ucts. Hand Brake Fluid Level 1. Position the A TV on a level surface. Position the handlebars so the m aste[...]

50 Features and Controls Parking Brake 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 bra ke lock inward 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 automati- [...]

51 Features and Con trols Parking Brake The parking br ake may relax if left o n for a long period of time. Always bloc k the wheels to prevent rolling. Always block th e wheels on the downhill side of the A TV if leaving it parked on a hill. Another option is to park t he A TV in a sidehill position. Never depend on the pa rking brake alone if the[...]

52 Features and Controls Manual Shif t Shif t Pedal 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[...]

53 Features and Con trols Manual Shif t Shif ting Ge ars Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopp ed position, place the transmission in neutral. 2. Squeeze and hold the brake lever . Do not apply throttle. 3. Squeeze the clutch lever to disengage the clutch. 4. Depress the gear shift pedal one full[...]

54 Features and Controls Manual Shif t Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse uninten- tionally . The switch must be manually unlocked before shifting into reverse gear . The lock will automatic ally re -engage when the transmission is shifted out of reverse gear . 1. Place the transmiss[...]

55 Features and Con trols Manual Shif t 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 . Be sure the engine RPM has suffic iently decreased before shifting to a lower gear . W ARNING! I[...]

56 Features 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 66 for correct choke and throttle settings during starting. Fuel T ank The fuel tank filler cap is located directly below the handlebar . Polaris recommends the use[...]

57 Features and Con trols Fuel V alve The fuel valve is located on the right side of the A TV . It has three positions: OFF: For vehicle storage and when transporting. T urn the fuel valve off whenever the vehicle is stored or parked. ON: For normal operation. RES: For reserve supply if main supply is exhausted. There's about a 5 to 8 mile (8 [...]

58 Operation Failure to operate the A TV properly can result in a co llision, loss of control, a ccide nt or overturn, which may result in se rious injury or d eath. Read an d unde rstand all safet y warning s outl ined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new Polaris A TV is the first three [...]

59 Operation Break-In Period Perform the following break-in and maintenance procedures carefully . 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever han- dling gasoline. 2. Check the oil level. Add the recom- mended oil as needed to maintain the oil level in the pro per range. See page 97 . 3. Allow the engine suf ficien[...]

60 Operation Pre-Ride Inspection Failure to inspect and verify that the A TV is in safe operating co ndition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Pre-Ride Check list P age Brake systems / lever travel En sure proper operation 46-51 144-145 Bra[...]

61 Operation Pre-Ride Inspection Pre-Ride Check list P age Coolant (if applicab le) Ensure proper level 107 Coolant hoses (if ap plicable) Inspect for leaks -- Throttle Ensure smooth operation 44 Indicator lights / switches Ensure operation 40, 41 Engine stop switch Ensure proper ope ration 39 Air filter Inspect, clean, replace as needed 110 Air bo[...]

62 Operation Safe Operation Practices 1. Complete the re commended safety training before operating this vehicle. See page 10. 2. Do not allow anyon e under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical dis- abilities to operate this vehicle. 3. Never carry a passenger on this A TV . 4. Engine ex haust fume[...]

63 Operation Safe Operation Practices 8. Drive in a mann er appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hand s from the han- dlebars wh ile operating, an d always keep both feet on the footpeg s. 9. Never consum e alcohol or drugs before o[...]

64 Operation Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulatio ns concerning the oper ation of this of f-road vehicle in your area. Respect the environment in which you ride. Find out where the desig- nated riding areas are by contacting your Polaris dealer , a local riding club or local officials. Help keep our[...]

65 Operation T rail Etiquette Always practice go od etiquette when r iding. Allow a safe distance betwee n your vehicle and other vehicles operatin g in the same area. Com m unicate to oncoming operators by signaling the numb er of vehicles in y our group. When stopping, mov e your vehicle to the edge of the trail as far as possible to allow others[...]

66 Operation S t arting the Engine The engine can be start ed when the transmissi on is in neutral, or while in gear if t he clutch is disengaged. If starting a warm engine, do not use the choke. Fuel is injected into the inta ke passage each time the thro ttle lever is depressed. Do not depress the throttle lever while starting the engine . Do not[...]

67 Operation S t arting the Engine 5. Move the engine stop switch to the RU N position. T urn the ignition key to ON. 6. If starting the engine while in gear , apply the hand brake and squeeze the clutch lever fully to disengage the clutch. If starting the e ngine while in neutral, the neutral indicator light should be on. If it isn't, disenga[...]

68 Operation Driving Procedure 1. W ear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on th e handleb ars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . See page 52. 5. Check you r surroundings and determi ne your path of travel. 6. Release the parking brake. 7. Slowl[...]

69 Operation Making T urns Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at a ll 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 ghtly . T o turn, steer in the direction of the turn, leaning your upper body to th[...]

70 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 ca use skids. 3. Correct a skid by t[...]

71 Operation Driving on Slippery Surfaces 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of th e skid an d shifting your body weig ht forward. Sideways skid Tu r n i n direction of skid[...]

72 Operation Driving Uphill Braking and handling are greatly affected when operating in h illy terrain. Improper procedure could cause loss of control or overturn. Whenever tr aveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrain carefully before ascending any hill. 4.[...]

73 Operation Driving Uphill 5. Keep both feet on the footp egs. 6. Shift body weight uph ill. 7. Proceed at a steady rate of speed and thro ttle opening. Opening the throttle suddenly could cause the A TV to flip over backwards. 8. Never back do wn a hill. W ARNING! Aggressively applying the fo ot brake when b acking down a hill may cause rear tipo[...]

74 Operation Driving on a Sidehi ll (Sidehilling) Driving on a sideh ill is not recom mended. Imprope r procedure co uld cause loss of control or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper [...]

75 Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uph ill. T ra nsfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when trav- eling downhill can cause loss of control. 5. Shift to the lowest gear possibl[...]

76 Operation T urning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Us e the K-turn to turn around: 1. Keep your body weight uphill. 2. Pull in the clutch lever and apply the front and rear brakes. 3. When completely stopped, shut of f the engi ne. Leaving the transmission in gear , release the clutch le[...]

77 Operation T urning Around on a Hill 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 s till applied, release the clutch lever and lock the parking brake. Remount from the up[...]

78 Operation Parking 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 urn th e engine off. 2. Place the transmission in fi rst 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.[...]

79 Operation Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before oper- ating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. T ravel sl owly and use extra caution when operating on unfamiliar [...]

80 Operation Driving Through W ater Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these procedures when operating through water: 1. Determine water depth and current before entering water . 2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. 3. A void operat[...]

81 Operation Driving Through W ater NOTICE: Serious engine damage can result if the vehi cl e is n ot thoroughly inspected after operatin g in water deeper than the footpeg level. As s oon as possible, perform the inspectio ns and maintenance services ou tlined in the periodic maintenan ce chart begin ning on page 85. Engine oil and all grease fi t[...]

82 Operation Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or peop le behind the vehicle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly while back- ing. Do not operate at ful[...]

83 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 qu[...]

84 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicl e are controlled by engine design , including factory-set fuel delivery and ignition. The en gine and related compon ents must be main- tained at Polaris specifications to achieve optimal pe rformance. Engine idle speed is the only adjustment P[...]

85 Maintena nce Periodic 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 recomm ended maintenance[...]

86 Maintenance Periodic Maintenance Chart The recommended se rvice intervals are based on aver age riding conditions. V ehicles sub- jected to severe use must be inspected and serviced more frequently . Severe Use Definition • F requent immersion in mud, water or sand • Racing or race-style high RPM use • Prolonged low sp eed, heavy load oper[...]

87 Maintena nce Periodic Maintenance Chart Improperly performing the pr ocedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an autho rized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations mo re often under severe use. E Emis[...]

88 Maintenance Periodic 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. 60 Tires -- - - Wheels/lug nuts -- -- F rame fasteners -- -- Coolant -[...]

89 Maintena nce 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

90 Maintenance Periodic 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 145 Rear sprocket bolts 10 Monthly -- Check torque 149 Battery 10 Monthly -- Check terminals; clean; test 129 X E Air filter 15 Weekly -- Inspect;[...]

91 Maintena nce 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

92 Maintenance Periodic 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 T [...]

93 Maintena nce 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

94 Maintenance Periodic 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 -- 156 [...]

95 Maintena nce 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 Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

96 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 85. 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 app lication[...]

97 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 damag[...]

98 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginni ng on page 85. Change the oil more frequen tly on vehicles subjected to severe use. IMPORT ANT : Perform the initial break-in oil cha nge after the first three h ours of operation. Alwa ys change both oil filters and clean t he[...]

99 Maintena nce Engine Oil Change 1. Position the vehicle on a level surface. 2. Remove the skid plate for better access to the oil drain pl ug and short screen . 3. S tart the engine. Al low it to idle for two to three minutes. S top the engi ne. 4. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain completely .[...]

100 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Short Oil Screen Plug View from bottom o f vehicle Fr o n t O -Rings[...]

101 Maintena nce Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine. See illustration on preceding pag e. 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. Rei[...]

102 Maintenance Engine Oil Change Cleaning the Long 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 si[...]

103 Maintena nce Engine Oil Change Cleaning the Long 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. NOTICE: An improperly installed oil screen will function poorly and result in incre ased engine wear . Install the sc[...]

104 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[...]

105 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 96). Reinstall the fill plug. 9. S tart the engine. All ow it to idle for at lea[...]

106 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 [...]

107 Maintena nce Engine Cooling System Coolant Level The reco very bottle i s located on the right side of the vehicle under the front fender . If the fluid level is vis- ible at the bottom of the side panel, add 6 oz. (175 ml) of coolan t. As coolant operating te mperature increases , the expanding (heated) excess coolant is forced out of the radi[...]

108 Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dry , inspect the level in the radiator and add coolant if necessary . The radiator pressure cap is located on the le ft side of the vehicle. CAUTION! Escaping stea m can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allo[...]

109 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[...]

110 Maintenance Air Filter Systems Refer to the illustrations on page 1 1 1. 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 foam fil[...]

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

112 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 S peed Carburetor idle adjustments affect engine starting behavior . A proper idle speed of 1500-1600 RPM will result in easier starting. [...]

113 Maintena nce Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be g inning on page 85. 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[...]

114 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 [...]

115 Maintena nce Light s Headlight Adjustment 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. S tart the engine and turn the headlight switch to high beam. 2 " (5 [...]

116 Maintenance Light s 4. Observe the headlight aim on the wall. The most intense part of the headlig ht beam should be aimed 2" (5 cm) below the mark placed on the wall. Include rider weight on the seat when measuring. 5. Loosen the pivot screw and adjust the beam to the desired position. 6. T ighten the screw and torq ue to 27 in. lbs. (3 N[...]

117 Maintena nce Light s Headlight Lamp Replacement When servicing a halogen lamp, avoid touchin g the lamp with bare fingers. Oil from yo ur skin leaves a residue, cau sing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. 1. Remove the wire harness connecto r from the back of the headl[...]

118 Maintenance Light s Headlight Assembly Replacement 1. Remove the front cover . 2. Remove the wire harness connector from the headlights. 3. Remove the two retaining brac kets and the adjuster screw . 4. Remove the headlamp. 5. Install the new headlamp, placing it in the sl ots on the fram e tabs. Se cure the headlamp with the retaining brackets[...]

119 Maintena nce Light s Brake Light Adjustment Check the rear brake light 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 do[...]

120 Maintenance Front Cab/Side Panel Removal The front cab and side panel assembly is remove d in one piece. 1. Remove the seat. 2. Remove the tw o front cover screws and remove the front cover . 3. Remove the eight side panel screws (four on each side). 4. Remove the fuel cap. 5. Gently pull the side panel/cab assembly upward and rearward. 6. Unpl[...]

121 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 an d grommets (2) on the top of the cab. 4. Remove the two bolts (3) at the rear cab-to-front-cab joint. 5. Unplug the taillight connector . 6. Remove the cab. 1 3 2[...]

122 Maintenance S p ark Plugs Refer to the specifications section beginning on page 168 for recommended spark plug type and gap NOTICE: Using non-recommended spark plugs can result in serious engine damage. Alwa ys use Polaris-recomme nded spark plugs. Spark plug condition is indicativ e of engine operat ion. The spark plug firing end condition sh [...]

123 Maintena nce S p ark 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. The tip should not be white. A white insulator tip indicates overh eating, cause d by use o f [...]

124 Maintenance S p ark Arrestor Clean-Ou t Failure to hee d the following w arnings while servici ng the spark arrestor could result in se rious injury or death. The exhau st system can get extremely hot. Do not perform service on the sp ark arrestor while the system is hot. Allow components to cool sufficiently before proceed ing. Remove any comb[...]

125 Maintena nce S p ark Arrestor Clean-Ou t T o remove ac cumulated carbon, clean the spark arrestor at the intervals recommended in the Peri- odic Maintenance Chart beginni ng on page 85. 1. Remove the retaining screw and remove the screen from the end o f the muf fler . 2. Use a non-synthetic brush to clean the arres- tor screen. A synthetic bru[...]

126 Maintenance V ehicle Immersion If the vehicle tips or overturns in water deeper than the footpeg level, o r if the engine stops during or after operating in water , restartin g WILL result in serious engine da mage. T ra ns- port the vehicle to your dealer for service befo re restarting the engine. If this is not possible, follow the vehicle im[...]

127 Maintena nce V ehicle Immersion 1. T urn the fuel valve off. 2. Drain water from the air box and cl ean the air filter . See page 1 10. 3. Drain the carburetor bowl. See page 1 13. 4. Remove the spark pl ug. See page 122. W ARNING! Fluids will be ejected through the spark plug hole and may cause se rious injury to face or other body part s. W e[...]

128 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[...]

129 Maintena nce Battery Improperly connecting or discon nec ting battery cabl es can re sult in an expl osion and cause serious injury or death. When removing the battery , alwa ys disconnect th e negative (black) ca ble first. When reinstalling the battery , always conne ct the negativ e (black) cable last. The seal ed battery is already fi lled [...]

130 Maintenance Batter y S torage Whenever the vehicle is not used for a period of three month s 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. D[...]

131 Maintena nce Battery Inst allation Always install a fully char ged battery . Using a new battery that has not been fully char ged can damage the battery and result in a shorter lif e. It can also hinder vehicle performance. If recharging is necessary , use a .5 amp battery charger . 1. Place the battery in the batte ry holder . 2. Connect and t[...]

132 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 . W ARNING! An overheated battery could explode, causin g severe in[...]

133 Maintena nce Battery Charging (Sealed Battery) The Polaris Battery T ender batte ry char ger can be left connected during the storage period and will automatically char ge the battery if th e voltage drops below a pre-determined point. If the battery fails to recharge during vehicle operation, che ck voltage regulator conne ctions. See your Pol[...]

134 Maintenance Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of char ging. 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% 12.5 [...]

135 Maintena nce Ti r e s Operating your A TV with worn tires, imprope rly inflat ed tires, non-standard tires or improperly inst alled tires will affect vehicle handling and co uld cause an accident resul ting in serious inju ry or death. Al ways follow all tire maintenance proced ures as outline d in this manua l and on the labels on the vehi cle[...]

136 Maintenance Wheel Nut T o rque S pecifications Check the wheel nut torques occasionally and wh en they've been loo sened for maintenance. Wheel Hub Ti ghtening 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 [...]

137 Maintena nce Wheel Inst allation 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 th[...]

138 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. Af ter Operating Inspect the boots after operating the vehicle. If a boot is bulging or balloo ned, perform the boot b urping procedure on page 139. G[...]

139 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. Do not use any tool s 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 boot away from the shaft to allow excess air to escape (2). 3. W i[...]

140 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Main tenance Chart beginnin g on page 85. 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 43. 1. Position the vehicle on a level su[...]

141 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. TIP: Extract fluid fro m the master cylinder du ring the process to prevent overflow ing. 6. When finished, remove the bleeder s[...]

142 Maintenance Throttle Lever Freeplay 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 143. 1/16 " - 1/8" (1.5 - 3 mm)[...]

143 Maintena nce Throttle Cable Freeplay Adjustment Improper adjustment of throttle cab le freeplay can result in loss of control, whi ch could result in serious injury or death. Polaris recommends that this proc edure be performe d by a Polaris dealer to e nsure that it's done correctly . Mechanica lly knowle dgeable p ersons who perform this[...]

144 Maintenance Brakes 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. T o ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosen ed or removed. Do [...]

145 Maintena nce Brakes 1. Always maintain brake fluid at the recommended level. See pages 48 -49. 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[...]

146 Maintenance To e A l i g n m e n t Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a ne utral toe setting. W ARNING! Severe injury or death can result from im proper toe a lignment a nd ad justment. Do not attempt to adjust tie rod ali gnment. All tie ro d adjustments should be performed by an [...]

147 Maintena nce To e A l i g n m e n t 4. Measure the distance between the marks and record the measurement (1). 5. Move the vehicle until the chalk marks are at the rear of the tires, even with the hub/axle center line. 6. Measure the distance between the marks and record the measurement (2). 7. Subtract measurement 2 from measure- ment 1. The di[...]

148 Maintenance Chain T ension CAUTION! Never adjust or operate th e vehicle with the re a r drive chain too loo se or too tight. Severe damage to the transmission and drive components can result. Check the amount of ch ain slack by moving the vehi cle slightly forward to remove sl ack at the top side of the chain. At the center point of the top si[...]

149 Maintena nce Chain T ension 3. T ighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4. T orque the chain adjusting bolt to 17 ft. lbs. (23 Nm). 5. Check sprocket bo lts to make sure the retainer tabs fit tig htly against the bolt heads. If not, tighten the bolts t o 28 ft. lbs. (38 Nm). 6. Bend the retaining tabs tightly against the flat e[...]

150 Maintenance Handlebar Adjustment Improper adjustment of th e handleba rs or incorre ct torquing of the ad juster blo ck tightening bolts can cause limited steeri ng or loosening of the handlebars, resulti ng in loss of control. Foll ow the adjustment procedures exactly , or see your Polaris dealer for service. The handlebars can be adjusted for[...]

151 Maintena nce S teering 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.[...]

152 Maintenance Front Suspension 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. The tires should be bare ly touching the g round and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of [...]

153 Maintena nce Front 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 ste[...]

154 Maintenance Front Suspension S pring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. W ARNING! Uneven adjustment may caus e poor handling of the A T V , which co uld result in an accident and serious inj ury or death. Alwa ys adjust both th e left and right spring preloads equall y o[...]

155 Maintena nce Front Suspension S pring 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. T urn the ring counter-clockwise to decrease preload. 4. T ighten the jam nut firm ly against the adjusting[...]

156 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 vehic le by placing a suitable stand under the frame. The tires should be bare ly touching the g round and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of th[...]

157 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[...]

158 Maintenance Rear Suspension The rear suspension spring preload and shock compression damping may be adjusted to su it dif ferent riding conditions and operator weight. S pring Preload 1. Raise and safely support the rear of the vehicle off the ground to allow the suspen sion to fully extend. 2. Loosen the jam nut. 3. T urn the adjusting ring cl[...]

159 Maintena nce 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 firmest setting, turn the screw clockwise until it stops (fully closed position). From this position, turn the sc rew counter -clockw[...]

160 Maintenance Cleaning Keeping your vehicle clean will not only impr ove its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage compo nents. Polaris recommends washing the vehicle by hand or with a garden h ose, using mild soap. Certain products, including insect repellents and chemicals, will[...]

161 Maintena nce Cleaning W ashing the V ehicle W ashing Tips • A void the use of harsh cleane rs, which can scratch the finish. • Do not use a power washer to clean the vehicle. • Do not use medium to heavy duty compounds on th e finish. • Always use clean cloths an d pads for cleaning and polish ing. Old or reused cl oths and pads may con[...]

162 Maintenance 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 components an d could remove paint and decals. If warning and safety labels are damaged, contac t your Pola ris dealer for free replacement. A void direct- ing the water stream at the [...]

163 Maintena nce Polishing Polaris recommends the use of common household aerosol furniture polish for pol ishing 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 your vehi- cle. • Always use clean cloths an d pads for[...]

164 Maintenance Sto r a g e Engine Oil Change the oil and both filters. Cl ean the oil screens. See page 98. 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 85. • [...]

165 Maintena nce Sto r a g e S t abilize the Fuel 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 container for the recommended amount. Carb on Clean removes water from fuel systems, stabilizes fuel and remove s car bon deposits from pistons, rings, valves[...]

166 Maintenance Sto r a g e Lubricate Inspect all cables and lubricate all areas of the vehicle as recomme nded in the Periodic Main- tenance Chart beginning o n page 85. S torage 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 vehicl[...]

167 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[...]

168 S pecifications Outlaw 525 IRS Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45 Dry Weight 389 lbs./176 kg Main Jet 148 F uel Capacity 3.1 gal./11.7 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./13[...]

169 S pecifications 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 10R10 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 G[...]

170 Polaris Product s 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[...]

171 Polaris Product s 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.)[...]

172 T roubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine T urns Over , Fails to S t art 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 tu[...]

173 T roubleshoot ing Engine T urns Over , Fails to S t art 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 volt[...]

174 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[...]

175 T roubleshoot ing 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 instal[...]

176 T roubleshooting Engine Runs Irregularly , St alls 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 [...]

177 T roubleshoot ing Engine Runs Irregularly , St alls 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 mechan[...]

178 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Le an F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean 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[...]

179 T roubleshoot ing Engine Fails to Reach High RPM Engine Uses Excessive Oil Possible Caus e Solution W orn or dirty needle valve Clean and/or replace needle 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 C[...]

180 T roubleshooting Engine S top s or Loses Power 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 Pol[...]

181 T roubleshoot ing Engine S top s or Loses Power 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 Se[...]

182 T roubleshooting Engine Overheat s 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 f[...]

183 T roubleshoot ing Engine Fails to Reach Full Powe r 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 Fault[...]

184 Wa r r a n t y 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 nt[...]

185 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[...]

186 Wa r r a n t y 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 ARRANTI[...]

187 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). [...]

188 Wa r r a n t y 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[...]

189 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 [...]

190 Wa r r a n t y 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, an[...]

191 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[...]

192 Wa r r a n t y 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 BR[...]

193 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[...]

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

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

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

197 Index A Age Restrictions . . . . . . . . . . . . . . 15 Air Filter Systems . . . . . . . . . 110-111 B Battery Charging . . . . . . . . . . . . . 132-134 Installation . . . . . . . . . . . . . . . 131 Maintenance . . . . . . . . . . . . . 129 Removal . . . . . . . . . . . . . . . . . 130 Storage . . . . . . . . . . . . . . 130, 163 Bleeding the[...]

198 Index F Fluid Brake . . . . . . . . . . . . . . . . . . 48-49 Clutch . . . . . . . . . . . . . . . . . . . . 43 Foot Brake . . . . . . . . . . . . . . . . . . . 46 Foot Brake Flui d Level . . . . . . . . . 49 Fuel Filter . . . . . . . . . . . . . . . . . . . . 56 Fuel Safety . . . . . . . . . . . . . . . . . . . 17 Fuel Stabilizer . . . . . . .[...]

199 Index P Parking Brake . . . . . . . . . . . . . . 50- 51 Parking on a Hill or In cline. . . . . . 78 Passenger Warnin g . . . . . . . . . . . . 37 Periodic Maintenance Ch art . . . 85-95 Polaris Products . . . . . . . . . . . . . 170 Polishing . . . . . . . . . . . . . . . . . . . 163 Pre-Ride Inspe ction . . . . . . . . . . 60-61 R Restriction[...]

200 Index S Side Panel Remo val . . . . . . . . . . . 120 Sidehilling . . . . . . . . . . . . . . . . . . . 74 Signal words . . . . . . . . . . . . . . . . . . . 6 Spark Arrestor Clean-Out. . . 124-125 Spark Plugs . . . . . . . . . . . . . . 12 2-123 Spring Prelo ad . . . . . . . . . . . . . . . 1 54 Spring Prelo ad, Front . . . . . . . . . . 155 S[...]