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2010 Polaris Outlaw 525 IRS Owners Manual

2010 Polaris Outlaw 525 IRS Manual

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2010 Polaris Outlaw 525 IRS | Owners Manual - Page 1
2010 Outlaw 525 IRS Owner's Manual for Maintenance and Safety This Category "S" (Sport) ATV is a high-performance ATV for off-road use skills and substantial experience. Operation is prohibited for anyone under 16 years of age. Read this manual carefully. It contains important safety information.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 2
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.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 3
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 4
on hills and rough terrain and in turns. avoid paved surfaces - pavement may seriously affect handling and control READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 5
Visit us at www.polarisindustries.com 1
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 6
reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 OUTLAW 525 IRS ATV Owner's Manual P/N 9922483 2
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 7
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 8
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 9
Table of Contents Introduction ...6 Safety ...10 Features and Controls ...38 Operation ...58 Emission Control Systems ...83 Maintenance ...85 Specifications ...168 Polaris Products ...170 Troubleshooting...172 Declaration of Conformity ...184 Warranty ...187 Maintenance Log ...199 Index ...203 5
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 10
on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 11
16 procedures before operating a Polaris ATV. years of age. Keep this manual with the ATV. • Never permit a guest to operate the ATV • Never operate an ATV without proper unless the guest has read this manual and all instruction. Take a training course. product labels and has completed a certified
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 12
. 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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 13
Introduction Vehicle Identification Numbers 1 2 Vehicle Model Number: _____ Frame Vehicle Identification Number (1): _____ Engine Serial Number (2):_____ Key Number (on the key): _____ 9
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 14
members who will be riding the ATV to take a training course. If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 15
with all laws and regulations concerning the operation of this vehicle in your area. Follow the recommended maintenance program outlined in your owner's manual. This program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals. FOR MORE
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 16
Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 17
Safety Safe 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 Helmet Long Sleeves Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 18
Safety Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 19
may result in serious injury or death. Heed all safety warnings outlined in this section of the owner's manual. See the OPERATION section of the owner's manual for proper operating procedures. Operator Restrictions/Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 20
Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of 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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 21
Safety Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 22
each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual. Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 23
Safety Safety Warnings Carrying a Passenger Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV. Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 24
Safety Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 25
Safety Safety Warnings Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience. Physical Control of the ATV
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 26
improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 27
Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 72. Operating on Steep Hills Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 28
descending a hill could cause loss of control or overturn. • Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 75. • Always descend a hill with the transmission in forward
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 29
. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 74. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 30
uphill side, or to either side if ATV is pointed straight uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. See page 76. 26
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 31
Safety Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 32
Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 82. Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 33
ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information. use extreme caution and always follow proper operating procedures as outlined in this manual. See page 79. Skidding or Sliding Skidding or sliding can cause loss
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 34
Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the footpegs
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 35
Safety Safety Warnings Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 36
risk of overturn and loss of control. Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. 32
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 37
Safety Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 38
have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 39
Never carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instruction • at speeds too fast for your skills or the conditions • on public roads - a affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376 35
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 40
Safety Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this ATV if you are under age 16. 7175374 Discretionary/Sport ATV Warning WARNING • Never operate this ATV on HILLS steeper than
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 41
Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 42
Features and Controls Engine Stop Switch Main Key Switch Start Button 38
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 43
Features and Controls Main Key Switch The main key switch must be in the RUN position to start the engine. See page 66 for starting procedures. Start Button Press the start button to engage the starter. Always release the start button promptly when the engine starts. If the starter fails to engage,
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 44
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 If indicator lights fail to operate, check connections. See your Polaris dealer for inspection of
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 45
Features and Controls Lights Headlights Use the headlight switch to turn the lights on and off and to switch the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Headlight Switch 41
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 46
to move the lever away from the handlebar. The adjustment range is limited. Never apply excessive force to the knob. Always turn the knob manually. Always check the lever for smooth operation before riding. If the lever does not operate smoothly, check the fluid level at the master cylinder
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 47
Features and Controls 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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 48
controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 49
Features and Controls Throttle Lever The throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to increase engine speed and vehicle movement. Fuel is injected into the intake passage each time throttle is applied. Do not squeeze the throttle lever while starting
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 50
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 51
can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. 47
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 52
Features and Controls Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 53
Features and Controls Master Cylinder/Brake Fluid 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 170 for the part numbers of Polaris products. Hand Brake Fluid Level 1. Position the ATV on a level surface
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 54
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 inward to engage the lock. Release the brake lever. 4. To release the parking brake lock, squeeze and release
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 55
Features and Controls Parking Brake The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 56
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 57
Features and Controls Manual Shift Shifting Gears Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral. 2. Squeeze and
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 58
Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally. The switch must be manually unlocked before shifting into reverse gear. The lock will automatically re-engage when the transmission is shifted out of reverse gear. 1. Place
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 59
Features and Controls Manual Shift Deceleration To slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 60
E-85 fuel. Fuel Filters The fuel pick-ups have internal fuel filters. Do not attempt to clean the fuel filters. See your Polaris dealer for service if you suspect the fuel filters are plugged. 56
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 61
Features and Controls Fuel Valve The fuel valve is located on the right side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. Turn the fuel valve off whenever the vehicle is stored or parked. ON: For normal operation. RES: For reserve supply if main supply is
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 62
, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. Break-In Period The break-in period for your new Polaris ATV is the first three hours of operation, or the time it takes to
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 63
Operation Break-In Period Perform the following break-in and maintenance procedures carefully. 1. Fill the fuel tank with gasoline. Always 5. Excessive heat build-up during the first exercise extreme caution whenever hanthree hours of operation will damage dling gasoline. close-fitted engine parts.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 64
Operation Pre-Ride Inspection Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Pre-Ride Checklist Brake systems / lever travel Brake
2010 Polaris Outlaw 525 IRS | 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 Rear shaft assembly Ensure proper level
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 66
Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 10. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Never carry a
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 67
type of tires specified for your vehicle. Always maintain proper tire pressure. 11. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage. 12. Never operate the ATV on a frozen body of water. 13. Do not touch hot
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 68
Operation Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 69
Operation Trail Etiquette Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 70
Operation Starting the Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. Fuel is injected into the intake passage each time the throttle lever is depressed. Do not depress the throttle
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 71
the start button, then activate the starter for another five seconds. Repeat until the engine starts. If the engine does not start, review the engine troubleshooting information beginning on page 172. If all conditions are favorable and the engine still does not start, see your Polaris dealer for
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 72
Operation Driving Procedure 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. See page 52. 5. Check your surroundings and determine your path of travel
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 73
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 74
Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns,
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 75
Operation Driving on Slippery Surfaces 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. Turn in direction of skid Sideways skid 71
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 76
Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25° maximum). 3. Always check the
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 77
Operation Driving Uphill 5. Keep both feet on the footpegs. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards. 8. Never back down a hill. WARNING! Aggressively applying the foot brake when
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 78
Operation Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Lean
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 79
Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Avoid steep hills (25° maximum). 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 80
Operation Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around: 1. Keep your body weight uphill. 2. Pull in the clutch lever and apply the front and rear brakes. 3. When completely stopped, shut off the engine. Leaving the
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 81
Operation Turning Around on a Hill 7. With the front brakes applied, pull in the clutch lever. Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward. 8. With the front brakes still applied, release the clutch lever and lock
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 82
Operation 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.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 83
Operation Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 84
Operation Driving Through Water Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these procedures when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and where both
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 85
if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 126, then see
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 86
Operation Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 87
Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 88
Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 89
Chart The high performance engine in your vehicle requires routine service to maintain the highest level of performance and reliability. Please read and follow the "Break-In Period" and "Maintenance" sections of your Owner's Manual carefully. Failure to perform the recommended maintenance procedures
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 90
intervals are based on average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed, heavy load operation
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 91
may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these operations more often under severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 92
Maintenance Periodic Maintenance Chart Item Brake systems/brake fluid Tires Wheels/lug nuts Frame fasteners Coolant Fuel Engine oil Transmission oil Throttle Clutch system/clutch fluid Lights Engine stop switch Steering Maintenance Interval (whichever comes first) Hours Calendar Fuel Used
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 93
Check idle speed setting Check torque Check; adjust 139 98 100 112 --- 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 89
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 94
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Brake pad wear Rear sprocket bolts Battery Air filter Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Shift lever bolt Valve clearance Clutches Spark plug 10 10 10 15 15 15 15
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 95
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 91
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 96
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Xz Xz Xz Xz Upper steering post (1) Front A-Arms (2) Stabilizer Bar (3) Rear Control Arm Needle Bearings (4) 45 45 45 90 Calendar 6M 6M 6M 12 M in gallons (liters) Remarks Fuel Used ----- Inspect;
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 97
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 93
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 98
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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 99
Inspect periodically; adjust when 146 parts are replaced Adjust as needed 115 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
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 100
on page 85. 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. Do not use Polaris PS-4 Performance Synthetic 10W-40 Oil. Always use 2W-50. See page 170 for the part
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 101
Maintenance 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 center of the sight glass. A high oil level can cause engine
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 102
Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Change the oil more frequently on vehicles subjected to severe use. IMPORTANT: Perform the initial break-in oil change after the first three hours of operation.
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 103
Maintenance Engine Oil Change 1. Position the vehicle on a level surface. 2. Remove the skid plate for better access to the oil drain plug and short screen. 3. Start the engine. Allow it to idle for two to three minutes. Stop the engine. 4. Place a drain pan beneath the crankcase. Remove the drain
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 104
Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Oil Screen Plug Front Short Screen O-Rings View from bottom of vehicle 100
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 105
Maintenance Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine. See illustration on preceding page. 2. Remove the short oil screen from the plug. Clean the screen components thoroughly and blow well with compressed air. 3. Check the O-
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 106
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 the
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 107
Maintenance Engine Oil Change Cleaning the Long Oil Screen 5. Insert the tool through the opening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. NOTICE: An improperly installed oil screen will function poorly and result
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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
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Maintenance Engine Oil Change Changing Oil Filters 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 1.7 qts. (1.6 l) of the recommended engine oil (see page 96). Reinstall the fill plug. 9.
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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
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Maintenance Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. If the fluid level is visible at the bottom of the side panel, add 6 oz. (175 ml) of coolant. As coolant operating temperature increases, the expanding (heated)
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Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dry, inspect the level in the radiator and add coolant if necessary. The radiator pressure cap is located on the left side of the vehicle. CAUTION! Escaping steam can cause burns. Never remove the pressure cap
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Maintenance Engine Cooling System 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,
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Maintenance Air Filter Systems Refer to the illustrations on page 111. 1. Remove the seat. 2. Release the airbox cover clips and remove the cover. 3. Loosen the filter clamp. Remove the air filter from the box. 4. Locate the retaining spring. 5. Carefully remove the retaining spring from the filter.
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Maintenance Air Filter Systems Step 3 Step 4 Step 5 Step 6 Step 7 111
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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-
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Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. 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
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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
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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
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Maintenance Lights 4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Include rider weight on the seat when measuring. 5. Loosen the pivot screw and adjust the beam to the desired position. 6. Tighten the
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the bulb housing and turn it counterclockwise to remove the bulb. CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 3. Apply dielectric grease to the socket and install the new bulb. Rotate firmly. The bulb must be positioned so the harness installs into the
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Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover. 2. Remove the wire harness connector from the headlights. 3. Remove the two retaining brackets and the adjuster screw. 4. Remove the headlamp. 5. Install the new headlamp, placing it in the slots on the frame tabs. Secure
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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
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Maintenance Front Cab/Side Panel Removal The front cab and side panel assembly is removed in one piece. 1. Remove the seat. 2. Remove the two front cover screws and remove the front cover. 3. Remove the eight side panel screws (four on each side). 4. Remove the fuel cap. 5. Gently pull the side
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Maintenance 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 and grommets (2) on the top of the cab. 4. Remove the two bolts (3) at the rear cab-to-front-cab joint. 5. Unplug the taillight connector. 6. Remove
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Maintenance Spark Plugs Refer to the specifications section beginning on page 168 for recommended spark plug type and gap NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation
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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. The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body
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the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustible materials from the area. Wear eye
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Maintenance Spark Arrestor Clean-Out To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 85. 1. Remove the retaining screw and remove the screen from the end of the muffler. 2. Use a non-synthetic brush to clean the
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engine stops during or after operating in water, restarting WILL result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined below. This procedure will
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Maintenance Vehicle Immersion 1. 2. 3. 4. Turn the fuel valve off. Drain water from the air box and clean the air filter. See page 110. Drain the carburetor bowl. See page 113. Remove the spark plug. See page 122. WARNING! Fluids will be ejected through the spark plug hole and may cause serious
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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
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Maintenance Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last
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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 maintain
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Maintenance Battery Installation 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. Place the battery in
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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. WARNING! An overheated
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Polaris dealer for inspection of the voltage regulator and generator. 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. 133
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Maintenance Battery Charging (Sealed Battery) 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 3
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will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Always ensure that all nuts are
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-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. 136 Stop the engine. Place the transmission in gear. Lock the parking
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Maintenance Wheel Installation 1. Place the transmission in gear. Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. 3. Install the wheel bolts and finger tighten them. 4. Lower the
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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
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Maintenance Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft
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Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system. See page
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Maintenance Clutch System Bleeding 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. TIP: Extract fluid from the master cylinder during the process to prevent overflowing.
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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 143. 1/16" - 1/8" (1.5 - 3 mm) 142
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Maintenance Throttle Cable Freeplay Adjustment 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. Mechanically
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Maintenance Brakes 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. To ensure proper diaphragm operation, always fill the reservoir as needed
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Maintenance Brakes 1. Always maintain brake fluid at the recommended level. See pages 48-49. 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
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Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod
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means that the front measurement should be 0" to 1/16" (0-1.5 mm) greater than the rear measurement. 9. If you discover improper alignment, see your Polaris dealer for service. 147
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the chain needs adjustment. TIP: The chain has a press-on master link. A chain tool must be used if it's necessary to remove the chain for service. 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
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Chain Tension 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4. Torque the chain adjusting bolt to 17 ft. lbs. (23 Nm). 5. Check sprocket bolts to make sure the retainer tabs fit tightly against the bolt heads. If not, tighten the bolts to 28 ft. lbs. (38 Nm). 6. Bend the retaining tabs
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steering or loosening of the handlebars, resulting in loss of control. 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
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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. 151
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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. The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measure the
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Maintenance Front Suspension 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,
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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
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Maintenance 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. Loosen the jam nut. 3. Turn the adjusting ring clockwise to
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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. The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measure the
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Maintenance Rear Suspension 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 suspension
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suspension spring preload 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. Loosen the jam nut. 3. Turn the adjusting
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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 firmest setting, turn the screw clockwise until it stops (fully closed position). From this
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Maintenance Cleaning Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products,
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Maintenance Cleaning Washing the Vehicle Washing Tips Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or
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Maintenance Cleaning 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. If warning and safety labels are damaged, contact your Polaris dealer for free replacement.
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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. •
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Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 98. 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
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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. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons
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on page 85. 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. Do not
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Maintenance 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.
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Specifications OUTLAW 525 IRS Max. 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./97.5 kg 389 lbs./176 kg 3.1 gal./11.7 l 71.5 in./182
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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
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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,
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Polaris Products Part Number 2871323 2871534 2871326 2870652 2872189 2876335 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.) 171
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Declaration of Conformity Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. APPLICABLE EUROPEAN
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Declaration of Conformity PRODUCT IDENTIFICATION VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___KA05__ ___KA09__ ___FA09__ ___VA17__ ___PB20__ ___BA32__ ___CA32__ ___BA50__ ___GJ45__ ___GJ52__, ___GP52__ ___LH27__ ___LH46__ ___MN50__ ___ZN55__ ___ZX55__ ___TN55__, ___DN55__ OUTLAW
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Declaration of Conformity VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___MN76__ ___TN85__, ___DN85__ ___CL76__ ___ZN85__, ___ZX85__ ___RH50__, ___HH50__ ___HH76__ ___WH76__ ___HR__ ___HY__ ___VH76__ Authorized Signatory: SPORTSMAN 800 SPORTSMAN X2/TOURING 850 SPORTSMAN 800 6X6
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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. 187
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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
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WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective
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Warranty LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment,
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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 DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN
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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
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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
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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
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U.S.A. EPA Emissions Limited Warranty Warranty This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
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Warranty U.S.A. EPA Emissions Limited Warranty For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Aftertreatment devices • Crankcase ventilation valves Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings
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U.S.A. EPA Emissions Limited Warranty 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
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responsible for performing the scheduled maintenance identified in the owner's manual. Polaris may deny warranty claims for failures that have been recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that
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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
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Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 60 90 200
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Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 201
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Maintenance Log DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 202
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Index Age Restrictions ...15 Air Filter Systems ...110-111 Battery Charging ...132-134 Installation ...131 Maintenance ...129 Removal...130 Storage...130, 163 Bleeding the Cooling System ...109 Boots ...14 Brake Fluid ...48-49 Brake Light Adjustment ...119 Brake Maintenance ...144-145 Brakes Foot
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118 Headlights ...41 Helmet ...13 Idle Speed ...112 Indicator Lights ...40 Instruction, Operating ...16 Jetting ...114, 169 Key Switch ...39 K-Turn ...76 Main Key Switch ...39 Maintenance Chart ...85-95 Making Turns ...69 Manual Shift ...52-55 Master Cylinder ...48-49 Modifications ...12 Oil Change
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Hills ...23 Operating Over Obstacles ...29 Operating Through Deep Water 30 Operating Without Instruction . 16 Physical Control of the ATV . . 21 Physical Skills ...32 Drugs...19 Safety Words and Symbols ...6 Service Requirements ...8 Severe Use...86 Shift Pedal ...52 Shifting Gears ...53 S 205
2010 Polaris Outlaw 525 IRS | Owners Manual - Page 210
Index Side Panel Removal ...120 Sidehilling ...74 Signal words...6 Spark Arrestor Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...154 Spring Preload, Front ...155 Spring Preload, Rear ...158 Starting the Engine ...66-67 Steering Inspection ...151 Storage ...163-166 Suspension Front ...