Owners Manual
Page 5
... quality of Polaris Industries Inc. Copyright 2008 Polaris Sales Inc. Due to constant improvements in this publication is based on the latest product information at the time of the depictions and/or procedures contained within this publication. Printed in part, is expressly prohibited. All information contained within , whether whole or in U.S.A. 2009 Outlaw 450 MXR/525 S ATV Owner's Manual P/N 9921801...
... quality of Polaris Industries Inc. Copyright 2008 Polaris Sales Inc. Due to constant improvements in this publication is based on the latest product information at the time of the depictions and/or procedures contained within this publication. Printed in part, is expressly prohibited. All information contained within , whether whole or in U.S.A. 2009 Outlaw 450 MXR/525 S ATV Owner's Manual P/N 9921801...
Owners Manual
Page 38
... in turns • avoid paved surfaces - NEVER operate: • without proper training or instruction • at speeds too fast for your skills or the conditions • on public roads - pavement may seriously affect handling and control. Never carry passengers. Always use an approved helmet and protective gear. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376 35 Safety Safety Labels and Locations General Warning WARNING Improper...
... in turns • avoid paved surfaces - NEVER operate: • without proper training or instruction • at speeds too fast for your skills or the conditions • on public roads - pavement may seriously affect handling and control. Never carry passengers. Always use an approved helmet and protective gear. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376 35 Safety Safety Labels and Locations General Warning WARNING Improper...
Owners Manual
Page 48
... to the rear wheels will stop, and power to increase engine speed and vehicle movement. If the throttle cable should stick in an open position when the operator releases the throtThrottle Lever tle lever, the engine will cease. 45 Do not squeeze the throttle lever while starting the engine. Fuel is injected into the intake passage each time throttle is stopped. Features and Controls Throttle Lever The throttle lever is...
... to the rear wheels will stop, and power to increase engine speed and vehicle movement. If the throttle cable should stick in an open position when the operator releases the throtThrottle Lever tle lever, the engine will cease. 45 Do not squeeze the throttle lever while starting the engine. Fuel is injected into the intake passage each time throttle is stopped. Features and Controls Throttle Lever The throttle lever is...
Owners Manual
Page 56
... throttle and disengaging the clutch could cause loss of control or vehicle overturn. Squeeze the clutch lever to additional gears. WARNING! When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke to shift into first gear. 5. Squeeze and hold the brake lever. Do not apply throttle. 3. Features and Controls Manual Shift Shifting Gears Always allow a cold engine...
... throttle and disengaging the clutch could cause loss of control or vehicle overturn. Squeeze the clutch lever to additional gears. WARNING! When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke to shift into first gear. 5. Squeeze and hold the brake lever. Do not apply throttle. 3. Features and Controls Manual Shift Shifting Gears Always allow a cold engine...
Owners Manual
Page 62
.... Operation Break-In Period Perform the following break-in period (3 hours), change the engine oil and the long and short oil filters. Do not allow engine speed to maintain the oil level in the proper range. Vary throttle positions. Perform regular checks on fluid levels, controls and areas outlined on the daily 4. yourself with gasoline. Fill the fuel tank with vehicle operation and handling. 8. See page area...
.... Operation Break-In Period Perform the following break-in period (3 hours), change the engine oil and the long and short oil filters. Do not allow engine speed to maintain the oil level in the proper range. Vary throttle positions. Perform regular checks on fluid levels, controls and areas outlined on the daily 4. yourself with gasoline. Fill the fuel tank with vehicle operation and handling. 8. See page area...
Owners Manual
Page 80
Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Stay in the clutch lever, shift into neutral and restart the engine. 10. Follow proper procedures for additional speed control if necessary, until more level ground is reached. 11. Pull in first gear, using the brakes for driving downhill. See page 78. 77 Operation Turning Around on a Hill 9.
Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Stay in the clutch lever, shift into neutral and restart the engine. 10. Follow proper procedures for additional speed control if necessary, until more level ground is reached. 11. Pull in first gear, using the brakes for driving downhill. See page 78. 77 Operation Turning Around on a Hill 9.
Owners Manual
Page 94
... Polaris dealer perform these services Use Polaris Premium All Season Grease 91 See the Pre-Ride Checklist. 3 Break-in gallons (liters) Remarks Fuel Used ------ Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Outer clutch cover -----Calendar Pre-ride in 5 (20) E X E Q z Change the oil and filters Clean screen and plug magnet Check idle speed...
... Polaris dealer perform these services Use Polaris Premium All Season Grease 91 See the Pre-Ride Checklist. 3 Break-in gallons (liters) Remarks Fuel Used ------ Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Outer clutch cover -----Calendar Pre-ride in 5 (20) E X E Q z Change the oil and filters Clean screen and plug magnet Check idle speed...
Owners Manual
Page 98
... tank cap, lines, fuel valve, filter, carburetor; clean external surface; measure; replace as needed Visual inspection for wear Perform these procedures more often for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 replace lines every two years Inspect; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling...
... tank cap, lines, fuel valve, filter, carburetor; clean external surface; measure; replace as needed Visual inspection for wear Perform these procedures more often for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 replace lines every two years Inspect; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling...
Owners Manual
Page 100
... Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid Jet needle/needle jet Brake fluid Spark arrestor Front/rear wheel bearings Toe adjustment Headlight aim X E Q z 90 90 -90 180 180 300 300 Calendar --in gallons (liters) Remarks Fuel Used 156 (600) 156 (600) ------- change yearly 138 Replace Replace Clean out 124 Inspect; adjust as needed Bleed as needed Inspect; replace as needed 116 Perform these services Use Polaris...
... Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid Jet needle/needle jet Brake fluid Spark arrestor Front/rear wheel bearings Toe adjustment Headlight aim X E Q z 90 90 -90 180 180 300 300 Calendar --in gallons (liters) Remarks Fuel Used 156 (600) 156 (600) ------- change yearly 138 Replace Replace Clean out 124 Inspect; adjust as needed Bleed as needed Inspect; replace as needed 116 Perform these services Use Polaris...
Owners Manual
Page 119
Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 Position the vehicle on the wall at the same height. 3. Start the engine and turn the headlight switch to the center of the headlight and make a mark on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Maintenance Lights Headlight Adjustment 1.
Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 Position the vehicle on the wall at the same height. 3. Start the engine and turn the headlight switch to the center of the headlight and make a mark on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Maintenance Lights Headlight Adjustment 1.
Owners Manual
Page 120
lbs. (3 Nm). The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Loosen the pivot screw and adjust the beam to 27 in. Observe the headlight aim on the wall. Pivot Screw 117 Include rider weight on the seat when measuring. 5. Tighten the screw and torque to the desired position. 6. Maintenance Lights Headlight Adjustment 4.
lbs. (3 Nm). The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Loosen the pivot screw and adjust the beam to 27 in. Observe the headlight aim on the wall. Pivot Screw 117 Include rider weight on the seat when measuring. 5. Tighten the screw and torque to the desired position. 6. Maintenance Lights Headlight Adjustment 4.
Owners Manual
Page 121
... connector to the back of the lamp. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 118 Hot components can cause burns to cool before servicing. 3. Apply dielectric grease to remove the bulb. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol...
... connector to the back of the lamp. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 118 Hot components can cause burns to cool before servicing. 3. Apply dielectric grease to remove the bulb. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol...
Owners Manual
Page 122
Remove the front cover. 2. Secure the headlamp with the retaining brackets. 6. Maintenance Lights Headlight Assembly Replacement 1. Remove the headlamp. 5. Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Connect the wire harness to the headlamp. Install the adjuster screw, leaving it in the slots on the frame tabs. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Reinstall the front cover. 8. Remove the two retaining brackets and the adjuster screw. 4. Remove the wire harness connector from the headlight. 3.
Remove the front cover. 2. Secure the headlamp with the retaining brackets. 6. Maintenance Lights Headlight Assembly Replacement 1. Remove the headlamp. 5. Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Connect the wire harness to the headlamp. Install the adjuster screw, leaving it in the slots on the frame tabs. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Reinstall the front cover. 8. Remove the two retaining brackets and the adjuster screw. 4. Remove the wire harness connector from the headlight. 3.
Owners Manual
Page 171
Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 360 lbs./163 kg 3.1 gal./...Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 3 OBDVR 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm CDI 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E 0.6 mm / .024 in. Dry Sump/Internal Reservoir 168 Specifications Outlaw 450 MXR...
Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 360 lbs./163 kg 3.1 gal./...Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 3 OBDVR 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm CDI 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E 0.6 mm / .024 in. Dry Sump/Internal Reservoir 168 Specifications Outlaw 450 MXR...
Owners Manual
Page 172
All Front Brake Rear Brake Parking Brake Headlight Taillight Brakelight 20 x 6R10 18 x 10R9 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel Dual Beam (55w/60w) LED LED Outlaw 450 MXR Jetting Chart ALTITUDE Meters (Feet)... Position: #2 169 Front Tire Size - Reverse Rear Two-Wheel Drive 5-Speed Manual Shift 2.516 2.500 1.941 1.579 1.333 1.130 2.429 Tire Size - Rear Tire Pressure - Specifications Outlaw 450 MXR Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio -
All Front Brake Rear Brake Parking Brake Headlight Taillight Brakelight 20 x 6R10 18 x 10R9 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel Dual Beam (55w/60w) LED LED Outlaw 450 MXR Jetting Chart ALTITUDE Meters (Feet)... Position: #2 169 Front Tire Size - Reverse Rear Two-Wheel Drive 5-Speed Manual Shift 2.516 2.500 1.941 1.579 1.333 1.130 2.429 Tire Size - Rear Tire Pressure - Specifications Outlaw 450 MXR Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio -
Owners Manual
Page 192
... not be covered by warranty. however, you must present your ATV requires warranty service, you may also have other warranty terms will contact the appropriate personnel at Polaris. Spark Arrestor Polaris warrants that you may use of Polaris engine oil. 2. Engine Oil 1. We recommend the use any warranty issues. When requesting warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs. This warranty gives you specific legal rights...
... not be covered by warranty. however, you must present your ATV requires warranty service, you may also have other warranty terms will contact the appropriate personnel at Polaris. Spark Arrestor Polaris warrants that you may use of Polaris engine oil. 2. Engine Oil 1. We recommend the use any warranty issues. When requesting warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs. This warranty gives you specific legal rights...
Owners Manual
Page 194
... be required to present documentation of your move . You may be authorized to perform the warranty repair. You may be sure to contact Polaris Customer Assistance and the customs department of residence. Warranty EXPORTED VEHICLES How to Get Service In the country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from any authorized...
... be required to present documentation of your move . You may be authorized to perform the warranty repair. You may be sure to contact Polaris Customer Assistance and the customs department of residence. Warranty EXPORTED VEHICLES How to Get Service In the country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo identification from any authorized...
Owners Manual
Page 203
... Jetting Specifications Outlaw 450 MXR ...169 Outlaw 525 S ...171 Key Switch ...39 K-Turn ...75 Lights ...40-41, 116-119 Headlight Adjustment. 116-117 Headlight Assembly ...119 Headlights...41 Indicator Lights ...40 I J Main Key Switch ...39 Maintenance Chart ...87-97 Making Turns ...69 Manual Shift ...52-55 Master Cylinder ...48-49 Modifications ...12 Oil Change, Engine...100-107 Oil Level, Engine ...99 Oil Recommendations ...98 Operator Restrictions ...15 Parking Brake ...50-51 Parking on a Hill or Incline ...79 Passenger Warning ...37 Periodic Maintenance Chart...
... Jetting Specifications Outlaw 450 MXR ...169 Outlaw 525 S ...171 Key Switch ...39 K-Turn ...75 Lights ...40-41, 116-119 Headlight Adjustment. 116-117 Headlight Assembly ...119 Headlights...41 Indicator Lights ...40 I J Main Key Switch ...39 Maintenance Chart ...87-97 Making Turns ...69 Manual Shift ...52-55 Master Cylinder ...48-49 Modifications ...12 Oil Change, Engine...100-107 Oil Level, Engine ...99 Oil Recommendations ...98 Operator Restrictions ...15 Parking Brake ...50-51 Parking on a Hill or Incline ...79 Passenger Warning ...37 Periodic Maintenance Chart...
Owners Manual
Page 205
... Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...153 Spring Preload, Front ...154 Spring Preload, Rear ...155 Starting the Engine ...66, 67 Steering Inspection ...151 Storage ...162-165 Suspension Front ...153-154 Rear ...155-157 Suspension Settings ...152 Switches Engine Stop Switch ...39 Main Key Switch...39 Reverse Lock-Out Switch ...54 Start Button ...39 S Throttle Cable Freeplay...141 Throttle Lever ...44-45 Throttle Lever Freeplay...140 Tires Installation ...137 Removal ...136...
... Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...153 Spring Preload, Front ...154 Spring Preload, Rear ...155 Starting the Engine ...66, 67 Steering Inspection ...151 Storage ...162-165 Suspension Front ...153-154 Rear ...155-157 Suspension Settings ...152 Switches Engine Stop Switch ...39 Main Key Switch...39 Reverse Lock-Out Switch ...54 Start Button ...39 S Throttle Cable Freeplay...141 Throttle Lever ...44-45 Throttle Lever Freeplay...140 Tires Installation ...137 Removal ...136...