2007 Polaris Outlaw 525 Owners Manual

2007 Polaris Outlaw 525 Manual

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2007 Polaris Outlaw 525 manual content summary:

  • 2007 Polaris Outlaw 525 | Owners Manual - Page 1
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 2
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 3
    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.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 4
    Visit us at www.polarisindustries.com 1
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 5
    or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2007 Outlaw 525 ATV Owner's Manual P/N 9921123 2
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 6
    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 3
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 7
    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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 8
    Features and Controls ...50 Break-In Period...70 Pre-Ride Inspection ...72 Operation ...74 Emission Control Systems ...95 Maintenance ...97 Specifications ...186 Polaris Products ...188 Troubleshooting...190 Warranty ...202 Maintenance Log ...211 Index ...215 5
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 9
    responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. Vehicle Identification Numbers Record your vehicle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 10
    Vehicle Identification Numbers 1 2 Know Your Vehicle Vehicle Model Number: _____ Frame Vehicle Identification Number (1): _____ Engine Serial Number (2):_____ Key Number (on the key): _____ 7
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 11
    been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle. If any decal becomes Age 16 Discretionary
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 12
    avoid vehicle overturns on hills and rough terrain and in turns • avoid paved surfaces - pavement may seriously affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. 7172560 9
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 13
    Safety Decals Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7172559 Discretionary Warning • Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent flipover on
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 14
    , off-center, or unsecured loads will increase your risk of losing control. For stability on rough or hilly terrain, reduce speed and cargo. Read Owner's Manual for more detailed loading information. 7174881 11
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 15
    Safety Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 16
    Riding Gear Safety 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 17
    maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand the owner's manual and all warnings before operating a Polaris ATV. Operator Restrictions/Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 18
    priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible area. Follow the recommended maintenance program outlined in your owner's manual. This program is designed to ensure that all critical components
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 19
    symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE: A note will alert you to important information or instructions. 16
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 20
    Safety Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this manual and all labels carefully. Follow all operating procedures. • Never operate an ATV without proper
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 21
    before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner's manual. • Always keep both hands on the handlebars and both feet on the footpegs of the ATV during operation. • Always travel slowly and use
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 22
    Operator Safety • Never operate on excessively rough, slippery or loose terrain. • Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds. • Always have the ATV inspected by an
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 23
    weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible. • Always use proper procedures if you stall or roll backwards while climbing a hill. To avoid
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 24
    to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. Safety • Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable, travel slowly, balance your weight carefully, avoid
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 25
    Safety Operator Safety • Always check for obstacles or people behind the ATV before operating in reverse. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure. •
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 26
    Operator Safety 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 27
    WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800)
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 28
    Operator Safety Safety WARNING POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD Only operators with advanced skills and
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 29
    Safety Operator Safety WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates this ATV. Even though a child may be within the recommended age group for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 30
    Operator Safety Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 31
    Safety Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 32
    Operator Safety Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 33
    Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 34
    Operator Safety Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 35
    use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 32
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 36
    Operator Safety Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving. 33
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 37
    Safety Operator Safety WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV. WHAT CAN HAPPEN A wagon, sled or other object towed behind an ATV does not have brakes or steering. The object may overturn or collide with other objects and cause serious injuries. HOW TO AVOID THE HAZARD
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 38
    Operator Safety Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 39
    Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 40
    loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds.Never turn at excessive speed. 37
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 41
    Safety Operator Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If the operator's foot
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 42
    Operator Safety Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 25 degrees 25°. >25° 39
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 43
    could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual beginning on page 82. Always check the terrain carefully before ascending any hill. Never operate the ATV on hills steeper than 25 degrees 25
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 44
    of control or overturn. HOW TO AVOID THE HAZARD 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 88. Always check the terrain carefully before descending a hill. Shift
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 45
    Never try 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 86. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 46
    Operator Safety Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill. Apply
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 47
    large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. 44
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 48
    AVOID THE HAZARD Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as described in the owner's manual and on safety decals. WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 49
    Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 50
    genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo. WHAT CAN HAPPEN Overloading or carrying/towing cargo can cause changes in
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 51
    severe injury or death. WARNING Operating a damaged ATV can result in an accident with serious injury or death. 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. 48
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 52
    Operator Safety Safety WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use. WARNING Exhaust system components are very hot during and after use of the vehicle. Hot
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 53
    Features and Controls Main Key Switch Engine Stop Switch 50 Start Button
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 54
    Main Key Switch Start Button Features and Controls The main key switch must be in the RUN position to start the engine. See page 75 for starting procedures. Press the start button to engage the starter. Always release the start button promptly when the engine starts. NOTE: If the starter fails to
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 55
    Features and Controls 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 NOTE: If indicator lights fail to operate, check connections. See your Polaris dealer for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 56
    Lights Headlights Features and Controls WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. This vehicle is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 57
    knob counterclockwise to move the lever closer to the handlebar. Turn the adjusting knob clockwise to move the lever away from the handlebar. knob manually. Adjusting Knob NOTE: The adjustment range is limited. Never apply excessive force to the knob. Always turn the Always check the lever for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 58
    Clutch Fluid The clutch fluid master cylinder is located on the left handlebar. Check the fluid level in the reservoir before each ride. The level should be 4mm below the upper edge of the reservoir. Do not overfill. Polaris recommends the use of KTM Hydraulic Clutch Oil. Do not use brake fluid. Do
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 59
    and lead to severe injury or death. Never start or operate the vehicle with an improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 60
    Throttle Lever Features and Controls This ATV is equipped with an 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.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 61
    Features and Controls 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 62
    Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar. Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes. Always test brake lever travel and master cylinder fluid level
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 63
    Features and Controls Master Cylinder/Brake Fluid Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 64
    Master Cylinder/Brake Fluid Features and Controls 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 188 for the part numbers of Polaris products. NOTE: When checking the fluid level, the ATV must be on
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 65
    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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 66
    Parking Brake Important Safeguards • 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.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 67
    Features and Controls 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 68
    Manual Shift Shifting Gears Features and Controls NOTE: Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 69
    Features and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally. 1. Place the transmission in first gear. See
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 70
    Manual Shift Features and Controls Deceleration To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 71
    E-85 fuel. Fuel Filter The fuel valve 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. 68
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 72
    Fuel Valve The fuel valve is located on the left side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. Features and Controls NOTE: There's about a 5 to 8 mile (8 to 13 km) range on
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 73
    Break-In Period Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. 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. Do not allow engine
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 74
    Break-In Period 1. Fill the fuel tank with gasoline. See page 74. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 109. 3. Allow the engine sufficient time to warm up before operating. 4. Drive slowly at first. Select an open area that
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 75
    Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Pre-Ride Checklist Brake systems / lever travel Brake fluid Clutch lever Clutch fluid
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 76
    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 Rear shaft assembly Ensure proper level Inspect for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 77
    Operation Fuel System WARNING 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 78
    Starting the Engine Operation 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. NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 79
    Operation 1. 2. 3. 4. 5. 6. Starting the Engine Shift the transmission to neutral. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle. Disengage the clutch. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine. 7. Move the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 80
    start button, then activate the starter for another five seconds. Repeat until the engine starts. NOTE: If the engine does not start, review the engine troubleshooting information beginning on page 190. If all conditions are favorable and the engine still does not start, see your Polaris dealer for
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 81
    Operation Driving Procedure 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up. 3. Shift the transmission into gear. See page 64. 4. Check your surroundings and determine your path of travel. 5. Release the parking brake. 6.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 82
    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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 83
    Operation Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 84
    Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 85
    injury or death. Avoid climbing steep hills (25° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. 82
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 86
    Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25° maximum). 3. Keep both feet on the footpegs. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 87
    Operation Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. 84
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 88
    Driving Across Hillsides Operation If you enter into a situation where sidehilling 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. Steer slightly into the hill to maintain
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 89
    or death. Avoid climbing steep hills (25° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary to turn
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 90
    Turning Around on a Hill Operation 6. Reach across the handlebar and apply the front brakes to unlock the parking brake. 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 91
    Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid in slowing.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 92
    Parking on a Hill or Incline Avoid parking on a hill or incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 93
    Operation Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 94
    the maintenance chart. If your vehicle becomes immersed or is operated in water that exceeds the footpeg level, take it to your dealer for service before starting the engine. NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you cannot avoid water that exceeds the recommended
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 95
    Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always look left, right and behind the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 96
    death. Before shifting into reverse, always check for obstacles or people behind the vehicle. Follow the reverse operation procedures outlined in this manual. This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use just enough throttle to maintain a desired
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 97
    Operation Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 98
    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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 99
    Emission Control Systems 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. Exhaust Emission Control System The emissions from the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 100
    . Please read and follow the "Break-In Period" and "Maintenance" sections of your Owner's Manual carefully. Failure to perform the recommended procedures at the service intervals specified in your owner's manual will void warranty coverage and decrease the performance and reliability of your vehicle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 101
    the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Severe Use Definition Frequent immersion
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 102
    failure and lead to serious injury or death. 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
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 103
    Maintenance Item Periodic Maintenance Chart Maintenance Interval (whichever comes first) Hours Calendar Fuel Used Remarks See Page Brake systems/brake fluid Tires Wheels/lug nuts Frame fasteners Coolant Fuel Engine oil Transmission oil Throttle Clutch system/clutch fluid Lights Engine stop
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 104
    Check idle speed setting Check torque Check; adjust 155 110 112 124 --- 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 101
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 105
    Maintenance Item Periodic Maintenance Chart Maintenance Interval (whichever comes first) Hours Brake pad wear Battery Air filter Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Clutches Spark plug 10 10 15 15 15 15 15 15 30 30 Calendar Monthly Monthly
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 106
    daily; adjust; lubricate if needed See your Polaris dealer Inspect strength seasonally 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 103
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 107
    Maintenance Item Periodic Maintenance Chart Maintenance Interval (whichever comes first) Hours Xz Xz Xz Xz Xz Upper steering post (1) Front A-Arms (2) Rear Control Arm Bushings (3) Stabilizer Bar (4) Rear Control Arm Needle Bearings (5) 45 45 45 45 90 Calendar 6M 6M 6M 6M 12 M in gallons (liters)
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 108
    every two years Inspect; 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 105
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 109
    spring cap Camshaft bearings Valve springs Valve seats/guides Rocker arm rollers Timing chain Cam chain E E E See your dealer or refer to the Dealer Service Manual; measure ring gap and replace if at or below service limit Visual inspection for wear Visual inspection for wear Replace See your
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 110
    Inspect periodically; adjust when 162 parts are replaced Adjust as needed 128 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 107
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 111
    page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. See page 188 for the part numbers of Polaris products. NOTE: Do not use Polaris PS-4 Performance Synthetic 10W
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 112
    Engine Oil Level Check the oil level before each use of the vehicle. If the engine is cold, the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible at the upper edge of the sight glass. 1. Position the vehicle on a level surface.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 113
    Maintenance Engine Oil Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filters within a few hours of
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 114
    Engine Oil Change Maintenance 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 3. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain completely. CAUTION Hot oil can cause serious burns
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 115
    Maintenance Engine Oil Change Cleaning the Short Oil Screen Hex Plug Front Short Screen View from bottom of vehicle 112
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 116
    Engine Oil Change Cleaning the Short Oil Screen Maintenance 1. Insert a hex key into the plug at the bottom of the engine. See illustration on preceding page. 2. Using a hammer, tap lightly on the key a few times to loosen the seal. Remove the plug. 3. Remove the short oil screen. Clean the screen
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 117
    Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen plug, located on the side of the engine near the engine number. 2. Remove the oil screen. Clean the screen thoroughly and blow with compressed air. 3. Check the O-rings. If damaged, install new O-rings. 4. Place
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 118
    Engine Oil Change Cleaning the Long Oil Screen Maintenance CAUTION An improperly installed oil screen will function poorly and result in increased engine wear. Install the screen securely at the angle shown in the illustration. 5. Insert the tool through the opening and into the bore of the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 119
    Maintenance Engine Oil Change Changing Oil Filters 1. Place a drain pan under the engine. 2. Remove the four oil filter cover screws (1). Remove the covers. 3. Using circle clip (snap ring) pliers, pull the oil filter inserts (2) out of the housing. 4. Thoroughly clean the engine casing, filter
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 120
    Engine Oil Change Changing Oil Filters Maintenance 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. Tighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fill plug (4). Add 40 oz. (1.2 liters) of the recommended engine oil (see page 108). Reinstall the fill plug.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 121
    Maintenance Engine Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose. To ensure that the coolant maintains its ability to protect the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 122
    Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL and ADD marks on the side panel (when the fluid is cool). As coolant operating temperature increases, the expanding (heated)
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 123
    Maintenance Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level If the recovery bottle has run dry, inspect the level in the radiator and
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 124
    Engine Cooling System Maintenance Cooling System Bleeding Bleeding the cooling system is required only if the system has been drained for maintenance and/or repair. Always allow the engine to cool sufficiently before removing the radiator pressure cap. 1. Remove the pressure cap. 2. Using a funnel
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 125
    Maintenance Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover. 3. Loosen the filter clamp. 4. Remove the air filter. 5. Remove the inner and outer foam filter elements from the internal cage. Foam Filter Element Clips Cage Retaining Ring Clamp 122
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 126
    Air Filter Systems 6. 7. 8. 9. Maintenance Wash the filters in soapy water, then rinse and let dry. Apply a commercially available foam filter lubricant to the foam filters. Reinstall all components. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 123
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 127
    Maintenance Carburetor Normal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and the needle jet after every 180 hours of operation. Idle Speed Carburetor idle adjustments affect engine starting behavior. A proper idle speed of 1500-
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 128
    Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. Turn the fuel valve off. 2. Place a suitable
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 129
    Maintenance Carburetor Jetting Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 130
    Lights Maintenance When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing frequently to maintain lighting quality. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled sufficiently. 127
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 131
    Maintenance Lights Headlight Adjustment 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine and turn the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 132
    Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb. 3. Apply dielectric
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 133
    Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp. 5. Install the new headlamp
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 134
    Lights Maintenance Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. Adjust for approximately 1/16" clearance between the bracket and the edge of the headlight. Tighten the mounting screws. IMPORTANT: Be sure the bracket is 90 degrees to the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 135
    Maintenance Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle. 1. Turn the ignition key on. 2. Lightly apply and release the foot brake several times. A properly operating rear brake light will immediately flash on and off with each movement
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 136
    Front Cab Removal 1. Remove the left and right cab mount screws (1). 2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2). 4. Remove the four side panel screws (3). 5. Gently pull the cab upward to disengage it
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 137
    Maintenance 1. 2. 3. 4. Side Panel Removal Unlatch and remove the seat. Remove the front cab. Remove the two screws securing the side panel. Remove the side panel. Side Panel Screws 134
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 138
    Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove the cab. 2 3 Maintenance 1 135
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 139
    Maintenance Spark Plugs Refer to the specifications section beginning on page 186 for recommended spark plug type and gap. CAUTION Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polaris-recommended spark plugs. Spark
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 140
    be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 141
    Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right side of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft. lbs. (19 Nm). Spark Plug 138
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 142
    Spark Arrestor Clean-Out Maintenance To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 97. WARNING Failure to heed these warnings could result in serious injury or death. Do not perform clean-out immediately
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 143
    Maintenance Spark Arrestor Clean-Out Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 144
    Spark Arrestor Clean-Out Maintenance 3. Inspect the screen for wear and damage. Replace a worn or damaged screen. 4. Remove and inspect the gasket (4). Replace a worn or damaged gasket. 5. Reinstall the gasket and arrestor. Torque screws to 50 in. lbs. (5.6 Nm). 141
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 145
    an ATV has been in water that exceeds the recommended depth. Serious engine damage WILL occur. Tow or trailer the ATV to your dealer for service. In an emergency, perform the temporary drying out procedure outlined below, which will allow short-term operation only, to drive the ATV to a trailer or
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 146
    Vehicle Immersion 1. 2. 3. 4. Turn the fuel valve off. Drain water from the air box and clean the air filter. See page 122. Drain the carburetor bowl. See page 125. Remove the spark plug. See page 138. Maintenance WARNING Fluids will be ejected through the spark plug hole and may cause serious
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 147
    than the pre-ride inspection level, water has entered the crankcase. Do not start the engine. Transport the vehicle to your dealer for inspection and service. If the oil level is unchanged from the pre-ride inspection level, replace the spark plug, start the engine and move the ATV promptly to
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 148
    Battery Maintenance The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 149
    Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 150
    Battery Installation Maintenance NOTE: Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger. 1. 2. 3. 4. 5.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 151
    Maintenance Battery Charging (Sealed Battery) On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is less than 12.8 volts, recharge the battery. The battery may be
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 152
    Battery Charging (Sealed Battery) Maintenance When using an automatic charger such as the Polaris Battery Tender, refer to the manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging. WARNING An overheated battery
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 153
    Maintenance Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge 100% 75%-100% 50%-75% 25%-50% 0%-25% Voltage 12.8-13.0 volts 12.5-12.8 volts 12.0-12.5 volts 11.5-12.0 volts 11.5 volts or less Action None, check at
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 154
    an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 155
    -35 ft. lbs. (40-47 Nm) Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Wheel Removal 1. 2. 3. 4. 152 Stop the engine. Place the transmission in gear. Lock the parking
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 156
    Wheel Installation Maintenance WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Never install the rim with the valve stem to the inside of the vehicle. Always ensure that all nuts are torqued to specification. 1.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 157
    Before Operating Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, see your Polaris dealer for service or replacement. After Operating Inspect the boots after operating the vehicle. If a boot is bulging or ballooned, perform the boot burping procedure
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 158
    Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. Maintenance 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 159
    Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system. See page
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 160
    Clutch System Bleeding Maintenance 4. Remove the bleeder screw (2) from the slave cylinder. 5. Press fluid into the system until the fluid runs out of the hole (3) in the master cylinder without producing bubbles. NOTE: Extract fluid from the master cylinder during the process to prevent
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 161
    Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are needed, use the procedure on page 159. 1/16" - 1/8" (1.5 - 3 mm) 158
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 162
    Throttle Cable Freeplay Adjustment Maintenance WARNING Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it's done correctly.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 163
    Maintenance Brakes WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill. Both brakes are self-adjusting, but the following checks are recommended to keep the brake
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 164
    Brakes 1. Always maintain brake fluid at the recommended level. See pages 60-61. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. 6.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 165
    Maintenance Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 166
    . The difference between these two measurements should be between 0" and 1/16" (0-1.5 mm) toe out. NOTE: If you discover improper alignment, see your Polaris dealer for service. Maintenance 1 String 4 2 3 Stands 163
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 167
    the chain needs adjustment. NOTE: The chain has a press-on master link. A chain tool must be used if it's necessary to remove the chain for service. 164
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 168
    Chain Tension Maintenance 1. Loosen the upper and lower pivot mounting bolts (1). 2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4. Torque the chain adjusting bolt to 17 ft. lbs. (
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 169
    in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference. 1. Loosen the four handlebar bolts. 2. Adjust the handlebar to the desired height. Be sure
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 170
    nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the steering post, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable. 167
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 171
    Maintenance Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 172
    Front Suspension Maintenance Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right. 8. With the rider still on the vehicle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 173
    Maintenance Front Suspension Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the left
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 174
    Front Suspension Spring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring clockwise to increase preload (1). Turn the ring counter-clockwise to decrease preload (2). Maintenance Adjusting Ring 1 2 171
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 175
    Maintenance Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the rear of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4.
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 176
    Rear Suspension Maintenance Suspension Set-Up 5. Remove the stand and have a rider sit comfortably on the seat with hands on the handlebars. 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 177
    Maintenance Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the softest position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments. Rear Shock Setting Softest Factory
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 178
    shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the vehicle off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring clockwise (1) to increase
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 179
    Maintenance Rear Suspension Compression Damping The compression damping clickers are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From this
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 180
    Cleaning Maintenance Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products,
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 181
    Maintenance Cleaning Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently. 3. Dry
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 182
    Cleaning Maintenance Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: • Wheel bearings • Brakes •
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 183
    Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. •
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 184
    Storage Maintenance CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and clean the vehicle as recommended. See page 177. Battery
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 185
    Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 110. Air Filter / Air Box Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 186
    Stabilize the Fuel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 187
    on page 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground. 4. Cover the vehicle with an appropriate cover. NOTE
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 188
    Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Remove the key to prevent loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. Turn the fuel valve off. 7. Always
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 189
    Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System See your owner's manual supplement or your Polaris dealer 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm CDI 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 190
    Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio - 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 - Front Tire Size - Rear Tire Pressure - All Front Brake Rear Brake Parking Brake Headlights
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 191
    Polaris Products Part Number 2876244 2876245 2871312 2871322 2871423 2871460 2871329 2872073 2872348 1350046 Description Engine Lubricant PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Grease / Specialized Lubricants Grease Gun Kit,
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 192
    Polaris Products Part Number 2871323 2871534 2871326 2870652 2872189 2876335 2872893 Description Coolant 60/40 Coolant (gal.) 60/40 Coolant (qt.) Additives / Miscellaneous Carbon Clean Plus (12 oz.) Fuel Stabilizer (16 oz.) DOT4 Brake Fluid (12 oz.) Hydraulic Clutch Oil (qt.) Engine Degreaser (12
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 193
    Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine Turns Over, Fails to Start Possible Cause Out of
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 194
    Troubleshooting Engine Turns Over, Fails to Start Possible Cause No spark to spark plug Overuse of choke/flooded engine Low battery voltage Ignition system or other
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 195
    Troubleshooting Engine Doesn't Turn Over Possible Cause Fuseable link Low battery voltage Loose battery connections Loose solenoid connections Solution See Polaris dealer for replacement Recharge battery
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 196
    Troubleshooting Engine Backfires Possible Cause Weak, fouled or defective spark plug Incorrect spark plug gap or heat range Old or non-recommended fuel Exhaust leak Incorrectly
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 197
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 198
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Clogged air filter Electronic throttle control malfunction Incorrect idle adjustment Clogged idle jet Other mechanical failure Solution
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 199
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Low or contaminated fuel Low octane fuel Old or non-recommended fuel Clogged fuel
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 200
    Troubleshooting Engine Fails to Reach High RPM Possible Cause Worn or dirty needle valve Loose carburetor jets Faulty ignition timing Solution Clean and/or replace needle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 201
    Troubleshooting Engine Stops or Loses Power Possible Cause Out of fuel Interrupted fuel supply Clogged, dirty or wet air filter Electronic throttle control malfunction Other mechanical
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 202
    Troubleshooting Engine Stops or Loses Power Possible Cause Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plug
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 203
    Troubleshooting Engine Overheats Possible Cause Debris lodged in screen Plugged radiator Insufficient coolant Insufficient air flow due to slow operation Cooling system has not been bled
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 204
    Troubleshooting Engine Fails to Reach Full Power Possible Cause Interrupted fuel supply Float leaks Clogged, dirty or wet air filter Faulty exhaust system Valve gap is
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 205
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 202
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 206
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 207
    Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 208
    THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 209
    Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 210
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the country where your vehicle
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 211
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 212
    Warranty U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 213
    Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 214
    Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 3 Hours (Break-in) 15 30
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 215
    Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 60 90 212
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 216
    Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 213
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 217
    Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 214
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 218
    Index Age Restrictions ...14 Air Filter Systems ...122-123 Arrestor, Spark ...140-141 Battery Charging...148-150 Installation ...147 Maintenance...145 Removal ...146 Storage ...146, 181 Bleeding the Cooling System ...121 Boots ...13 Brake Fluid ...60-61 Brake Light Adjustment ...132 Brake
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 219
    Headlight Assembly . . 130-131 Headlights...53 Indicator Lights ...52 I J K L Main Key Switch ...51 Maintenance Chart ...97-107 Making Turns ...79 Manual Shift ...64-67 Master Cylinder ...60-61 Modifications ...23 Oil Change, Engine...110-117 Oil Level, Engine ...109 Oil Recommendations ...108
  • 2007 Polaris Outlaw 525 | Owners Manual - Page 220
    Index Restrictions ...14 Reverse Lock-Out Switch ...66 Riding Gear...12-13 Safety Decals Age 16 Warning...10 Discretionary Warning...10 General Warning ...9 No Passenger Warning...11 Sport ATV Warning...10 Tire Pressure/Load Warning 11 Safety Training ...15 Severe Use ...98 Shift Pedal...64 Shifting
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