Polaris Outlaw 525 S User Manual

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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. 2009 Outlaw 450 MXR/525 S ATV Owner's Manual P/N 9921801

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 Pure Polaris products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

Table of Contents

Introduction. . . . . . . . . . . . . . . . . . 6

Safety . . . . . . . . . . . . . . . . . . . . . 10

Features and Controls . . . . . . . . 38

Operation . . . . . . . . . . . . . . . . . . 58

Emission Control Systems . . . . . 85

Maintenance . . . . . . . . . . . . . . . . 87

Specifications . . . . . . . . . . . . . . 168

Polaris Products . . . . . . . . . . . . 172

Troubleshooting. . . . . . . . . . . . . 174

Warranty . . . . . . . . . . . . . . . . . . 186

Maintenance Log . . . . . . . . . . . 195

Index . . . . . . . . . . . . . . . . . . . . . 199

Introduction

Safety Words and Symbols

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 indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

Introduction

WARNING

Failure to follow the warnings and safety precautions contained 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 this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a Polaris ATV. Keep this manual with the ATV.

• Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV

RiderCourse

Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

. Contact ATV Enrollment

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

• 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.

Introduction

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.

Introduction

Vehicle Identification Numbers

Vehicle Model Number:________________________________________________________________________

Frame Vehicle Identification Number (1): __________________________________________________________

Engine Serial Number (2):______________________________________________________________________

Key Number (on the key): ______________________________________________________________________

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

available to

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

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

by calling 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.

Safety

Safety 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.

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.

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.

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.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only Polaris-approved accessories, and familiarize yourself with their function and effect on the vehicle.

Safe Riding Gear

Helmet

Eye

Protection

Gloves

Boots

Long Pants

Long Sleeves

051039

0006.31

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.

Safety

Safe 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 Warnings

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

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.

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.

Safety

Safety Warnings

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.

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 RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

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.

offered by Polaris through the SVIA. They should then

contact ATV

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• 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 is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

Safety

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Safety

Safety Warnings

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

Protective Apparel

Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident.

Always wear 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.

Safety Warnings

Carrying a Passenger

Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV.

Safety

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating an ATV.

Safety

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads or highways could result in a collision with another vehicle. Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.

Safety Warnings

Operating at Excessive Speeds

Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.

Safety

Physical Control of the ATV

Removing a hand from the handlebars or feet from the footpegs during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footpeg, it could also contact the rear wheels.

Never remove your hands from the handlebars while operating, and always keep both feet on the footpegs.

Safety

Safety Warnings

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual.

Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Safety Warnings

>25°

Improper Hill Climbing

Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 72.

Safety

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees.

Safety

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

• Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 78.

• Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 74.

Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 75.

Safety

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a hill could cause 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 gradually (right lever). When fully stopped, apply the foot brake as well, and then lock the parking brake.

If the ATV begins rolling downhill: Keep weight uphill. Never apply engine power. Never apply the rear

brake while rolling backwards. Apply the front brake slowly. When fully stopped, apply the rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 75.

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

Safety

Safety Warnings

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 82.

Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.

Improper Tire Maintenance

Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Safety Warnings

Improper Vehicle Modifications

Improper installation of accessories or modification of the ATV may cause changes in handling, which could cause loss of control or an accident.

Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

Safety

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.

Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 84.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding.

Safety

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the footpegs:

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving. The friction will help dry out the pads.

Safety

Safety Warnings

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo may cause changes in handling, which could cause loss of control or an accident. Never haul cargo or tow a load with this ATV.

Never tow or pull an object behind the ATV. A wagon, sled or other towed object does not have brakes or steering. The object may overturn or collide with other objects.

Never exceed the stated load capacity for this ATV.

Safety

Safety Warnings

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice. Never operate the ATV on a frozen body of water.

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control.

Safety Warnings

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 traveling through tall grass, especially dry grass.

Safety

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use.

Safety

Age 16

Warning

General Warning

Discretionary/Sport ATV

Warning

Safety Labels and Locations

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

If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement.

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

Safety Labels and Locations

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 condi-

tions

• 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

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.

7175376

Safety

Safety Labels and Locations

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.

7175374

Discretionary/Sport ATV Warning

WARNING

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

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

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.

°. To prevent overturn on

7175637

Safety Labels and Locations

Tire Pressure

Warning

Passenger

Warning

No Passenger Warning

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

in SEVERE INJURY or DEATH.

7175378

Safety

Tire Pressure/Load Warning

WARNING Improper tire pressure or overloading can cause

loss of control. Loss of control can result in severe injury or

death.

• Cold tire pressure:

Front: 4.0 psi (27.6 kPa) Rear: 4.0 psi (27.6 kPa)

• Maximum Weight Capacity 215 lbs. (98 kg)

7175445

Features and Controls

Start

Button

Engine

Stop Switch

Main Key Switch

Features and Controls

OFF OFFRUN

Main Key Switch

The main key switch must be in the RUN position to start the engine. See page 66 for starting procedures.

Start Button

Press the start button to engage the starter. Always release the start button promptly when the engine starts. If the starter fails to engage, replace the blown fuse or see your Polaris dealer.

Engine Stop Switch

Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off.

Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Features and Controls

Reverse

Neutral

Hot Engine

Lights

Indicator Lights

An illuminated light in the indicator window will alert you to the following conditions.

• Hot engine

• 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.

Lights

Headlight Switch

Headlights

Use the headlight switch to turn the lights on and off and to change 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.

Features and Controls

Adjusting Knob

Clutch Lever

The hydraulic clutch lever is located on the left handlebar. Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears.

The clutch is self-adjusting, but lever position can be changed to fit the operator’s hand. Turn the adjusting knob counterclockwise to move the lever closer to the handlebar. Turn the adjusting knob clockwise to move the lever away from the handlebar.

The adjustment range is limited. Never apply excessive force to the knob. Always turn the knob manually.

Always check the lever for smooth operation before riding. If the lever does not operate smoothly, check the fluid level at the master cylinder. See page 43.

If the lever begins to feel unresponsive, bleed the clutch system as outlined on page 138.

Clutch Fluid

Screws

Cover

Boot

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 reservoir. Do not overfill.

Polaris recommends the use of KTM Hydraulic Clutch Oil. Do not use brake fluid. Do not mix clutch fluid with any other hydraulic fluids. See page 172 for the part numbers of Polaris products.

1. Position the vehicle on a level surface.

2. Turn the handlebar until the master cylinder is in a horizontal position.

3. Remove the two cover screws, the cover and the rubber boot.

4. Add the recommended fluid as needed.

5. Reinstall the cover, boot and screws securely.

Features and Controls

WARNING

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.

Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is properly installed to the throttle control.

Features and Controls

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 intake passage each time throttle is applied. Do not squeeze the throttle lever while starting the engine. Do not squeeze the throttle lever when the engine is stopped.

Engine speed returns to idle when the lever is released. See page 141 for throttle adjustment procedures.

This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

Features and Controls

Footpeg

Foot Brake

(Rear Brake)

Foot Brake

The foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding.

Check the brake fluid level frequently for the foot brake system. The reservoir is located under the seat. Maintain the fluid level between the minimum and maximum marks.

WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the foot brake. Do not aggressively apply the foot brake when going forward. The rear wheels may skid and slide sideways, causing loss of control.

Features and Controls

Hand Brake

(Front Brake)

Hand Brake

The hand brake operates the front brakes. The hand brake is located on the right handlebar. are hydraulically activated disc type brakes. the brake lever toward the handlebar to engage the front brakes.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING! Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

These brakes

Squeeze

Features and Controls

WARNING

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 recommended level. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.

Master Cylinder/Brake Fluid

Fluid Level Mark

Check the brake fluid in the master cylinder before each ride. If the fluid level is low add DOT 4 brake fluid only. Do not overfill. See page 172 for the part numbers of Polaris products.

Hand Brake Fluid Level

1. Position the ATV on a level surface. Position the handlebars so the master cylinder is level.

2. View the fluid level through the indicator window on the side of the master cylinder.

3. Maintain the fluid level at or slightly above the mark near the center of the sight glass. Do not overfill.

Foot Brake Fluid Level

1. Position the ATV on a level surface.

2. Remove the seat and view the fluid level in the reservoir. Maintain the fluid level between the maximum and minimum marks.

Features and Controls

Parking Brake

1. Place the transmission in first gear.

2. Squeeze and release the brake lever two or three times, then squeeze and hold.

3. Push the parking brake lock down to engage the lock. Release the brake lever.

4. To release the parking brake lock, squeeze and release the brake lever. The lock will automatically disengage.

WARNING! Operating the ATV while the parking brake is engaged could result in an accident. Always check to be sure the parking brake is disengaged before operating.

Features and Controls

Parking Brake

The parking brake may relax if 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 ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

Features and Controls

Upshift

Downshift

Manual Shift

Shift Pedal

The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released.

To upshift to a higher gear, place the toe of your boot under the gear shift pedal and raise the pedal one full stroke. See page 53.

To downshift, place your foot on the gear shift pedal and depress the pedal one full stroke. See page 53.

To shift into reverse, see page 54.

Manual Shift

Shifting Gears

Always allow a cold engine to warm up before shifting gears.

1. When starting from a stopped 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 stroke to shift into first gear.

5. Release the brake lever.

6. Gradually squeeze the throttle lever while slowly releasing the clutch lever.

Features and Controls

7. As engine speed (RPM) increases in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke. Repeat this procedure to progressively upshift to additional gears. Use the same procedure to downshift.

WARNING! Shifting without releasing the throttle and disengaging the clutch could cause loss of control or vehicle overturn. Always release the throttle and fully squeeze the clutch lever while shifting gears.

Features and Controls

Lock-Out Lever

Manual Shift

Reverse Lock-Out Switch

The reverse lock-out switch prevents the operator from shifting into reverse unintentionally. The switch must be manually unlocked before shifting into reverse gear. The lock will automatically re-engage when the transmission is shifted out of reverse gear.

1. Place the transmission in first gear. See page 52.

2. Push the lock-out lever forward toward the handlebar to unlock the transmission.

3. Shift down into reverse gear.

Features and Controls

Manual Shift

Deceleration

To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine speed decreases, disengage the clutch and shift to a lower gear. Be sure engine speed has sufficiently decreased before downshifting.

WARNING! Improper use of the brakes or shifting when the engine speed is too high can cause the tires to lose traction or stop rotating, which could result in loss of control.

NOTICE: Shifting when engine speed is too high can also cause engine and drive train damage.

Features and Controls

Choke Knob

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 Tank

The fuel tank filler cap is located directly below the handlebar. Polaris recommends the use of 91 octane or higher fuel. Do not use E-85 fuel.

Fuel Filter

The fuel tank has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged.

Fuel Valve

The fuel valve is located on the right side of the ATV. It has three positions:

OFF: For vehicle storage and when transporting. Turn the fuel valve off whenever the vehicle is stored or parked.

ON: For normal operation. RES: For reserve supply if main supply is

exhausted. There's about a 5 to 8 mile (8 to 13 km) range on reserve gas. Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.

Features and Controls

Operation

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-In Period

The break-in period for your new Polaris ATV is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both.

Do not allow engine speed to exceed 7000 RPM during the break-in period. Follow the break-in period with an additional 12 hours of cautious operation, with engine speed below 75% of capacity.

NOTICE: Failure to perform the recommended break-in maintenance can result in serious engine

damage.

Break-In Period

Perform the following break-in and maintenance procedures carefully.

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 99.

3. Allow the engine sufficient time to warm up before operating.

4. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

5. Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not allow engine speed to exceed 7000 RPM during the first three hours of use.

6. Vary throttle positions. Do not operate at sustained idle.

7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page

60.

8. At the end of the break-in period (3 hours), change the engine oil and the long and short oil filters. See page 100. Clean the oil screen and drain plug magnet.

Operation

Pre-Ride Inspection

Pre-Ride Checklist Page

Brake systems / lever travel Ensure proper operation 46-51

Brake fluid Ensure proper level 48

Clutch lever Check for proper operation and adjustment 42

Clutch fluid Ensure proper level 43

Suspension, front and rear Inspect, lubricate if necessary 94

Steering Check for free operation/loose components --

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 56, 99

142-143

Operation

Pre-Ride Inspection

Pre-Ride Checklist Page

Coolant (if applicable) Ensure proper level 109

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure smooth operation 44

Indicator lights / switches Ensure operation 40, 41

Engine stop switch Ensure proper operation 39

Air filter Inspect, clean, replace as needed 112

Air box sediment tubes Drain deposits when visible --

Headlamp Verify operation, apply Polaris dielectric grease to

Brake light / tail lamp Verify operation --

Riding gear Wear helmet, goggles, protective clothing 13

A-arm ball joints Check freeplay. If the tire moves excessively, do not

the socket when the lamp is replaced

operate. See your Polaris dealer.

118

Operation

Safe Operation Practices

1. Complete the recommended safety training before operating this vehicle. See page 10.

2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

5. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

6. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

7. Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads on the racks (if equipped) and the load on the trailer tongue (if equipped). The combined weight of these items must not exceed the maximum weight capacity.

Safe Operation Practices

8. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footpegs.

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

10. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

Operation

11. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.

12. Never operate the ATV on a frozen body of water.

13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

Operation

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

Operation

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

Operation

Choke Knob

Starting the Engine

The engine can be started 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.

Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the throttle lever while starting the engine. Do not depress the throttle lever when the engine is stopped.

NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine

1. Shift the transmission to neutral.

2. Lock the parking brake. Turn the fuel valve on.

3. Sit on the vehicle. Disengage the clutch.

4. If the engine is cold, pull the choke knob out until it

to warm up for several minutes before operating.

stops. Do not use the choke if starting a warm engine.

Operation

Starting the Engine

5. Move the engine stop switch to the RUN position. Turn 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 engine while 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 52.

7. Do not apply throttle. Press the start button to start the engine. Activate the starter for a maximum of five seconds. Release the start button immediately when the engine starts.

NOTICE: Excessive engagement may result in starter damage.

8. If the engine does not start, wait five seconds after releasing the start button, then activate the starter for another five seconds. Repeat until the engine starts. If the engine does not start, review the engine troubleshooting information beginning on page 174. If all conditions are favorable and the engine still does not start, see your Polaris dealer for service.

9. Push the choke knob completely in. Vary engine speed slightly with the throttle to aid in warm-up.

Operation

Driving Procedures

1. Wear a helmet and eye protection.

2. Sit upright with both feet on the footpegs and both hands on the handlebars.

3. Start the engine and allow it to warm up.

4. Shift the transmission into gear. See page 52.

5. Check your surroundings and determine your path of travel.

6. Release the parking brake.

7. Slowly depress the throttle with your right thumb while slowly releasing the clutch lever to begin driving.

8. Drive slowly. Practice maneuvering and using the throttle, clutch and brakes on level surfaces.

Operation

Making Turns

Your ATV 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 distance than the inside wheel when turning, and the inside tire slips traction slightly.

To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

Practice making turns at slow speeds before attempting to turn at faster speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

Operation

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

Operation

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

Operation

25° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25

3. Always check the terrain carefully before ascending any hill.

4. Never climb hills with excessively slippery or loose surfaces.

° maximum).

Operation

Driving Uphill

5. Keep both feet on the footpegs.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards.

8. Never back down a hill.

WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover.

9. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

10. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

Operation

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid 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 body weight uphill while keeping your feet on the footpegs.

3. If the vehicle begins to slide or tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

Operation

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! Use 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 off the engine. Leaving the transmission in gear, release the clutch lever and lock the parking brake.

4. Dismount on the uphill side of the vehicle, or on the left side if the vehicle is pointing straight uphill.

5. Staying uphill of the ATV, turn the handlebars full left.

6. Reach across the handlebar and apply the front brakes to unlock the parking brake.

Operation

8 ft. (2.4 m)

Turning Around on a Hill

7. With 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. With the front brakes still applied, release the clutch lever and lock the parking brake. Remount from the uphill side, keeping body weight uphill.

Operation

Turning Around on a Hill

9. Pull in the clutch lever, shift into neutral and restart the engine.

10. Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Stay in first gear, using the brakes for additional speed control if necessary, until more level ground is reached.

11. Follow proper procedures for driving downhill. See page 78.

Operation

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (25

2. Shift body weight uphill. Transfer your weight to the rear of the vehicle.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause loss of control.

5. Shift to the lowest gear possible while maintaining a safe speed.

6. Do not apply the brakes abruptly when driving downhill. Apply the foot brake slightly to aid in slowing.

° maximum).

Parking on a Hill or Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Place the transmission in first gear.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side. See illustration.

5. Turn the fuel valve off.

Operation

Maximum Depth

Driving Through Water

Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions 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. Avoid operating through deep or fast-flowing water.

Operation

Driving Through Water

NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating

4. After leaving water, test the brakes. Apply them lightly several times while driving. The

If it’s unavoidable to enter water deeper than the footpeg level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes.

in water deeper than the footpeg level. As soon as possible, perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 87. Engine oil and all grease fittings need special attention.

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 126, then see your dealer for service at the first opportunity.

friction will help dry out the pads.

Operation

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly while backing.

Operation

Driving in Reverse

7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.

8. Always look left, right and behind the ATV before backing.

NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the

exhaust, resulting in engine popping and/or engine damage.

Operation

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or fallen trees.

Emission Control Systems

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR

8343.1(c). Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Emission Control Systems

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

The emissions label is located on the front frame tube near the steering post.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.

Maintenance

Periodic Maintenance Chart

Routine inspection and service are critical to the performance and reliability of your high performance engine. Failure to perform the recommended maintenance procedures outlined in the Periodic Maintenance Chart will result in forfeited warranty coverage as well as decreased performance and reliability of the vehicle. If you're unable to perform the required

service and adjustment procedures, have a qualified dealer perform these operations.

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 195.

Maintenance

Periodic Maintenance Chart

The recommended service intervals are based on average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Maintenance

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often under severe use.

E Emission-related service (Failure to conduct this maintenance will not void the

emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

z Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2.

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Brake systems/brake fluid -Tires -- -Wheels/lug nuts -- -Frame fasteners -- -Coolant -- -Fuel -- -Engine oil -- -Transmission oil -- -Throttle -- -Clutch system/clutch fluid -- -Lights -- -Engine stop switch -- -Steering -- --

(whichever comes first)

Hours Calendar Fuel Used

Pre-ride

Remarks

Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist.

See

Page

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Air box sediment tubes -- Pre-ride -- Check each day before operating Headlamp -- -Tail lamp/brake lamp -- -A-arm ball joint -- -Rear shaft assembly -- -Oil and filter change Oil screen/drain plug Clean screen and plug magnet 102 Idle speed Check idle speed setting 113 Engine mounting bolts Check torque --

E Valve clearance Check; adjust --

Outer clutch cover Check 6 mounting screw torques --

X Perform these procedures more often for 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

(whichever comes first)

Hours Calendar Fuel Used

3 Break-in 5 (20)

in gallons (liters)

the vehicle. Make adjustments as needed. See the Pre-Ride Checklist.

Change the oil and filters 100

Remarks

See

Page

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Brake pad wear 10 Monthly -- Inspect regularly 143 Battery 10 Monthly -- Check terminals; clean; test 129

XE Air filter 15 Weekly -- Inspect; clean; replace as needed 112 X Oil and filter change 15 6 M 26 (100) Perform initial oil change after first

X Oil screen/drain plug 15 6 M 26 (100) Clean screen and plug magnet 102

Idle speed 15 6 M 26 (100) Check; adjust as needed 113 Engine mounting bolts 15 6 M 26 (100) Check torque -Shift lever bolt 15 6 M 26 (100) Check torque --

E Valve clearance 15 6 M 26 (100) Check; adjust --

Clutches 30 6 M 52 (200) Check discs for wear --

E Spark plug 30 6 M 52 (200) Replace 122

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

3 hours of operation.

Remarks

Page

See

100

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Xz General lubrication 45 3 M 78 (300) Lubricate all fittings, pivots,

Carburetor float bowl 45 6 M 78 (300) Drain bowl periodically and prior

QE Throttle cable/ETC switch 45 6 M 78 (300) Inspect; adjust; replace as needed 141

X Drive chain(s) 45 6 M 78 (300) Inspect daily; adjust; lubricate if

XQ Brake pad replacement 45 6 M 78 (300) See your Polaris dealer --

Coolant strength 45 6 M 78 (300) Inspect strength seasonally 108

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

cables, etc.

to storage

needed

Remarks

Page

See

114

146

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Xz Upper steering post (1) 45 6 M -- Inspect; tighten fasteners; grease after

Xz Front A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease (also Xz Rear axle/eccentric (3) 30 3 M --

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

washing ATV/driving in water

after washing ATV or driving in water)

Remarks

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Clutch springs 60 12 M 104 (400) Check spring length (see dealer) -Cam chain tensioner 60 12 M 104 (400) Check ratchet teeth for wear -Coolant system 90 12 M 156 (600) Pressure test system annually --

X Cooling system hoses 90 12 M 156 (600) Inspect --

Radiator 90 12 M 156 (600) Inspect; clean external surface;

QE Fuel system 90 12 M 156 (600) Check for leaks at tank cap, lines,

E Cylinder and piston 90 -- 156 (600) Inspect; measure; replace as

Piston pin circlip groove 90 -- 156 (600) Visual inspection for wear --

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

change coolant every 2 years

fuel valve, filter, carburetor; replace lines every two years

needed

Remarks

See

Page

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

E Compression ring 90 -- 156 (600) See your dealer or refer to the Dealer E Oil scraper ring 90 -- 156 (600)

Camshaft 90 -- 156 (600) Visual inspection for wear Valve spring cap 90 -- 156 (600) Visual inspection for wear

E Camshaft bearings 90 -- 156 (600) Replace E Valve springs 90 -- 156 (600) See your dealer or refer to the Dealer E Valve seats/guides 90 -- 156 (600) E Rocker arm rollers 90 -- 156 (600) E Timing chain 90 -- 156 (600) Measure elongation; replace as needed

Cam chain tensioner 90 -- 156 (600) Check ratchet teeth for wear

E Bearings (connecting rod,

balance shaft, crankshaft main)

Crankshaft run-out 90 -- 156 (600) Measure; adjust as needed

(whichever comes first)

Hours Calendar Fuel Used

90 -- 156 (600) Replace

in gallons (liters)

Service Manual; measure ring gap and replace if at or below service limit

Service Manual; perform measurements; replace as needed

Remarks

Maintenance

Periodic Maintenance Chart

Item Maintenance Interval

Oil pressure valve 90 -- 156 (600) Measure spring; replace as needed Transmission 90 -- 156 (600) Check entire transmission/bearings for

QE Ignition Timing -- 12 M -- Inspect; adjust as needed

Clutch fluid 90 12 M -- Bleed as needed; change yearly 138

QE Jet needle/needle jet 180 24 M -- Replace Q Brake fluid 180 24 M -- Replace

Spark arrestor 300 36 M -- Clean out 124

Q Front/rear wheel bearings 300 36 M -- Inspect; replace as needed Q Toe adjustment As required Inspect periodically; adjust when

Headlight aim As required Adjust as needed 116

(whichever comes first)

Hours Calendar Fuel Used

in gallons (liters)

wear; replace as needed

parts are replaced

Remarks

See

Page

144

Polaris Outlaw 525 S User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual