Owners Manual
Page 4
... handling and control READ OWNER'S MANUAL. WARNING NEVER operate: without proper training or instruction at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922479 Rev 02 Printed in SEVERE INJURY or DEATH. For your skills or the conditions...
... handling and control READ OWNER'S MANUAL. WARNING NEVER operate: without proper training or instruction at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922479 Rev 02 Printed in SEVERE INJURY or DEATH. For your skills or the conditions...
Owners Manual
Page 39
... use on public roads. LOCATE AND READ OWNER'S MANUAL. Never use an approved helmet and protective gear. Never use proper riding techniques to avoid vehicle overturns on public roads - a collision can result in turns • avoid paved surfaces - passengers affect balance and steering and increase risk of losing control ALWAYS: • use with a passenger - Safety Safety Labels and Locations General Warning WARNING Improper ATV use...
... use on public roads. LOCATE AND READ OWNER'S MANUAL. Never use an approved helmet and protective gear. Never use proper riding techniques to avoid vehicle overturns on public roads - a collision can result in turns • avoid paved surfaces - passengers affect balance and steering and increase risk of losing control ALWAYS: • use with a passenger - Safety Safety Labels and Locations General Warning WARNING Improper ATV use...
Owners Manual
Page 49
... throttle adjustment procedures. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is applied. Fuel is injected into the intake passage each time throttle is designed to idle when the lever is stopped. Features and Controls Throttle Lever The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to the rear wheels will stop, and power to increase engine speed and vehicle...
... throttle adjustment procedures. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is applied. Fuel is injected into the intake passage each time throttle is designed to idle when the lever is stopped. Features and Controls Throttle Lever The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to the rear wheels will stop, and power to increase engine speed and vehicle...
Owners Manual
Page 57
... vehicle overturn. Do not apply throttle. 3. Depress the gear shift pedal one full stroke. Repeat this procedure to progressively upshift to downshift. Squeeze the clutch lever to warm up before shifting gears. 1. As engine speed (RPM) increases in neutral. 2. Features and Controls Manual Shift Shifting Gears Always allow a cold engine to disengage the clutch. 4. When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear...
... vehicle overturn. Do not apply throttle. 3. Depress the gear shift pedal one full stroke. Repeat this procedure to progressively upshift to downshift. Squeeze the clutch lever to warm up before shifting gears. 1. As engine speed (RPM) increases in neutral. 2. Features and Controls Manual Shift Shifting Gears Always allow a cold engine to disengage the clutch. 4. When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear...
Owners Manual
Page 63
... of operation will damage dling gasoline. Drive slowly at sustained idle. 3. yourself with gasoline. See page 100. Do not operate at first. Perform regular checks on fluid levels, controls and areas outlined on the daily 4. Select an open pre-ride inspection checklist. Fill the fuel tank with vehicle operation and handling. 8. Do not allow engine speed to familiarize 60. At the...
... of operation will damage dling gasoline. Drive slowly at sustained idle. 3. yourself with gasoline. See page 100. Do not operate at first. Perform regular checks on fluid levels, controls and areas outlined on the daily 4. Select an open pre-ride inspection checklist. Fill the fuel tank with vehicle operation and handling. 8. Do not allow engine speed to familiarize 60. At the...
Owners Manual
Page 65
Operation Pre-Ride Inspection Pre-Ride Checklist Coolant (if applicable) Coolant hoses (if applicable) Throttle Indicator lights / switches Engine stop switch Air filter Air box sediment tubes Headlamp Brake light / tail lamp Riding gear A-arm ball joints Ensure proper level Inspect for leaks Ensure smooth operation Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Verify operation, apply Polaris dielectric grease to the socket when the lamp...
Operation Pre-Ride Inspection Pre-Ride Checklist Coolant (if applicable) Coolant hoses (if applicable) Throttle Indicator lights / switches Engine stop switch Air filter Air box sediment tubes Headlamp Brake light / tail lamp Riding gear A-arm ball joints Ensure proper level Inspect for leaks Ensure smooth operation Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Verify operation, apply Polaris dielectric grease to the socket when the lamp...
Owners Manual
Page 81
Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. See page 78. 77 Pull in first gear, using the brakes for driving downhill. Operation Turning Around on a Hill 9. 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.
Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. See page 78. 77 Pull in first gear, using the brakes for driving downhill. Operation Turning Around on a Hill 9. 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.
Owners Manual
Page 95
... 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 99
replace as needed Visual inspection for wear Perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, carburetor; change coolant every 2 years Check for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling system hoses Radiator Fuel system Cylinder and piston Piston...
replace as needed Visual inspection for wear Perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, carburetor; change coolant every 2 years Check for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling system hoses Radiator Fuel system Cylinder and piston Piston...
Owners Manual
Page 101
... ; replace as needed 116 Perform these services Use Polaris Premium All Season Grease 97 adjust when 144 parts are replaced Adjust as needed Inspect; Maintenance Periodic Maintenance Chart Item 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...
... ; replace as needed 116 Perform these services Use Polaris Premium All Season Grease 97 adjust when 144 parts are replaced Adjust as needed Inspect; Maintenance Periodic Maintenance Chart Item 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...
Owners Manual
Page 120
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. Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 Maintenance Lights Headlight Adjustment 1. 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. Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 Maintenance Lights Headlight Adjustment 1. Position the vehicle on the wall at the same height. 3.
Owners Manual
Page 121
Loosen the pivot screw and adjust the beam to 27 in. lbs. (3 Nm). Maintenance Lights Headlight Adjustment 4. Include rider weight on the wall. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Pivot Screw 117 Observe the headlight aim on the wall. Tighten the screw and torque to the desired position. 6.
Loosen the pivot screw and adjust the beam to 27 in. lbs. (3 Nm). Maintenance Lights Headlight Adjustment 4. Include rider weight on the wall. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Pivot Screw 117 Observe the headlight aim on the wall. Tighten the screw and torque to the desired position. 6.
Owners Manual
Page 122
... the socket and install the new bulb. Rotate firmly. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. Apply dielectric grease to skin. The bulb must be positioned so the harness installs into the lamp at outer side. 4. Oil from the back of the lamp. Remove the wire harness connector from your skin leaves...
... the socket and install the new bulb. Rotate firmly. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. Apply dielectric grease to skin. The bulb must be positioned so the harness installs into the lamp at outer side. 4. Oil from the back of the lamp. Remove the wire harness connector from your skin leaves...
Owners Manual
Page 123
Remove the two retaining brackets and the adjuster screw. 4. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Reinstall the front cover. 8. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Remove the headlamp. 5. Connect the wire harness to the headlamp. Remove the wire harness connector from the headlight. 3. Remove the front cover. 2. Maintenance Lights Headlight Assembly Replacement 1. Install the new headlamp, placing it loose so the headlight can be adjusted. 7.
Remove the two retaining brackets and the adjuster screw. 4. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Reinstall the front cover. 8. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Remove the headlamp. 5. Connect the wire harness to the headlamp. Remove the wire harness connector from the headlight. 3. Remove the front cover. 2. Maintenance Lights Headlight Assembly Replacement 1. Install the new headlamp, placing it loose so the headlight can be adjusted. 7.
Owners Manual
Page 174
Specifications OUTLAW 525 S Max. Dry Sump/Internal Reservoir 170 Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 370 lbs./168 kg 3.1 gal./11.8 l 71.5 ... Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 4 OBDVS 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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground ...
Specifications OUTLAW 525 S Max. Dry Sump/Internal Reservoir 170 Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 370 lbs./168 kg 3.1 gal./11.8 l 71.5 ... Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 4 OBDVS 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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground ...
Owners Manual
Page 199
... does not apply to perform the warranty repair. If you have received authorization for export. You must be requested from the country of the selling dealer's authorized location. EXPORTED VEHICLES Warranty 195 Upon residence verification, the servicing dealer will be authorized to Safety Recalls. Dealers may be done by an authorized Polaris dealer. EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE...
... does not apply to perform the warranty repair. If you have received authorization for export. You must be requested from the country of the selling dealer's authorized location. EXPORTED VEHICLES Warranty 195 Upon residence verification, the servicing dealer will be authorized to Safety Recalls. Dealers may be done by an authorized Polaris dealer. EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE...
Owners Manual
Page 209
... Consumer Product Safety...11 Coolant Level, Radiator ...110 Coolant Level, Recovery Bottle. . 109 Cooling System ...108-111 Cooling System Bleeding...111 C Deceleration ...55 Driving Downhill ...78 Driving in Reverse ...82-83 Driving on a Sidehill ...74 Driving on Slippery Surfaces . . 70-71 Driving Over Obstacles...84 Driving Procedures ...68 Driving Through Water...80-81 Driving Uphill ...72-73 Electronic Throttle Control ...45 Emission Control Systems ...85-86 Engine Idle Speed ...113 Equipment...
... Consumer Product Safety...11 Coolant Level, Radiator ...110 Coolant Level, Recovery Bottle. . 109 Cooling System ...108-111 Cooling System Bleeding...111 C Deceleration ...55 Driving Downhill ...78 Driving in Reverse ...82-83 Driving on a Sidehill ...74 Driving on Slippery Surfaces . . 70-71 Driving Over Obstacles...84 Driving Procedures ...68 Driving Through Water...80-81 Driving Uphill ...72-73 Electronic Throttle Control ...45 Emission Control Systems ...85-86 Engine Idle Speed ...113 Equipment...
Owners Manual
Page 210
... 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...
... 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...
Owners Manual
Page 212
... 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...