Polaris Outlaw 525 IRS, Outlaw 9920972 User Manual

WARNING

The engine exhaust from this

product contains chemicals known

to the State of California to cause

cancer, birth defects or other

reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.

Visit us at www.polarisindustries.com

information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2008 Outlaw 525 IRS ATV Owner's Manual P/N 9920972

Welcome

Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

Welcome

We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our Parts, Apparel and Accessories (PAA) products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Table of Contents

Know Your Vehicle . . . . . . . . . . . . 6

Safety Decals . . . . . . . . . . . . . . . . 8

Safety . . . . . . . . . . . . . . . . . . . . . 12

Features and Controls . . . . . . . . 50

Break-In Period. . . . . . . . . . . . . . 70

Pre-Ride Inspection . . . . . . . . . . 72

Operation . . . . . . . . . . . . . . . . . . 74

Emission Control Systems . . . . . 95

Maintenance . . . . . . . . . . . . . . . . 97

Specifications . . . . . . . . . . . . . . 186

Polaris Products . . . . . . . . . . . . 188

Troubleshooting. . . . . . . . . . . . . 190

Warranty . . . . . . . . . . . . . . . . . . 202

Maintenance Log . . . . . . . . . . . 211

Index . . . . . . . . . . . . . . . . . . . . . 215

Know Your Vehicle

The high performance engine in your vehicle requires routine service to maintain the highest level of performance and reliability. Please read and follow the “Break-In Period” and “Maintenance” sections of your Owner’s Manual carefully. Failure to perform the recommended procedures at the service intervals specified in your owner’s manual will void warranty coverage and decrease the performance and reliability of your vehicle.

As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Know Your Vehicle

Vehicle Identification Numbers

Vehicle Model Number:____________________________________________________________________

Frame Vehicle Identification Number (1): ______________________________________________________

Engine Serial Number (2):__________________________________________________________________

Key Number (on the key): __________________________________________________________________

Safety Decals

Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.

If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.

Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.

Age 16

Warning

Discretionary

Warning

General

Warning

Sport ATV

Warning

General Warning

WARNING Improper ATV use can result in SEVERE

INJURY OR DEATH. Always use an approved helmet and protective

gear. Never use on public 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

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk of losing control

Safety Decals

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.

7172560

Safety Decals

Age 16 Warning

WARNING Operating this ATV if you are under the age of 16

increases your chance of severe injury or death. NEVER operate this ATV if you are under age

16.

7172559

Sport ATV Warning

WARNING This ATV may exceed the performance of other

ATVs you may have ridden in the past. This category S (Sport) ATV is a high performance vehicle for off-road use only, in sport type recreation and competitive use by operators with advanced skills and substantial experience.

7173837

Discretionary Warning

• Never operate this ATV on HILLS steeper than 25 degrees 25 hilly terrain, use throttle and brakes gradually.

• REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

• PARKING BRAKE may relax when used for more than 5 minutes. When parking on grades, leave ATV in gear.

°. To prevent flipover on

7173837

No Passenger Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting

in SEVERE INJURY or DEATH.

7172566

Passenger

Warning

Tire Pressure

Warning

Safety Decals

Tire Pressure/Load Warning

WARNING IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) REAR 4 (27.6)

MAXIMUM WEIGHT CAPACITY 215 LBS. (97.5 KG) INCLUDES WEIGHT OF OPERATOR, CARGO

AND ACCESSORIES Reduce speed and allow greater distance for

braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. For stability on rough or hilly terrain, reduce speed and cargo.

Read Owner's Manual for more detailed loading information.

7174881

Safety

Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Helmet

Eye Protection

051039

0006.31

Long Sleeves

Gloves

Long Pants

Boots

Safety

Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of strong over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

Safety

Operator Safety

WARNING

Failure to follow the warnings in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than

other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand the owner's manual and all warnings before operating a Polaris ATV.

Operator Restrictions/Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. This category S (Sport) ATV is a high performance vehicle intended for off road use only, for sport-type recreation and for competitive use by operators with advanced skills and substantial experience.

Operator Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the

authorized ATV RiderCourse you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV

RiderCourse

You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

available to

Safety

If you purchased a used Polaris ATV, you can take the ATV RiderCourse

ATV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.

Follow the recommended maintenance program outlined in your owner's manual. This program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

by calling

Safety

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

Safety

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

• Read this manual and all labels carefully. Follow all operating procedures.

• Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and age eligible family members are entitled to take

the ATV RiderCourse

. Contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information

on enrollment in the ATV RiderCourse

• Never allow anyone under 16 years of age to operate this ATV.

• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.

• Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

Safety

Operator Safety

• Never operate an ATV on a public street, road or highway, including a dirt or gravel road.

• Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

• Never consume alcohol or drugs before or while operating an ATV.

• Never operate at excessive speeds. Travel at speeds appropriate for the terrain, visibility and operating conditions, and your experience.

• Never attempt jumps or other stunts.

• Never tow or pull an object behind the AT V.

• Always inspect your ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner's manual.

• Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation.

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain conditions.

Operator Safety

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident.

• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

Safety

• Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight uphill. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed

• Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Drive straight downhill.

Safety

Operator Safety

• Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose surfaces. Shift your weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

• Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

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 control.

• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

Safety

• Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

Safety

Operator Safety

• Always check for obstacles or people behind the ATV before operating in reverse. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles.

• Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure.

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

• Never modify an ATV through improper installation or use of accessories.

• Never exceed the stated load capacity for your ATV.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Safety

Operator Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, spray-

ers, or large racks, may change the handling characteristics of the vehicle. Use only Polarisapproved accessories, and familiarize yourself with their function and effect on the vehicle.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not

know how to operate the ATV properly in different situations and on different types of terrain.

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV

RiderCourse

regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.

For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800) 8872887 or visit www.atvsafety.org.

offered by Polaris through the SVIA. They should then

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD Only operators with advanced skills and substantial experience should operate this ATV.

Safety

Operator Safety

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum

age recommendation operates this ATV. Even though a child may be within the recommended age group for

operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE HAZARD No one under the age of 16 should operate this ATV. Only operators with advanced skills and

substantial experience should operate this ATV.

Operator Safety

WARNING

POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to

balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.

HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow

the operator to shift position as needed during operation. It is not intended for carrying passengers.

Safety

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