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Polaris Outlaw 9922479 Owner's Manual

Polaris industries all-terrain vehicles owner's manual
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Summary of Contents for Polaris Outlaw 9922479

  • Page 2 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 OR ALCOHOL avoid paved surfaces - pavement may seriously affect handling and control For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No.
  • Page 5 Visit us at www.polarisindustries.com...
  • Page 6 POLARIS, THE WAY OUT and OUTLAW are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • 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...
  • Page 8 We also take great pride in our Pure Polaris products, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

  • Page 9: Table Of Contents

    Specifications ....168 Polaris Products ... . 172 Troubleshooting... . . 174 Declaration of Conformity .

  • Page 10: Introduction

    Introduction Safety Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard.
  • Page 11 Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

  • Page 12: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
  • Page 13 Introduction Vehicle Identification Numbers Vehicle Model Number: ________________________________________________________________________ Frame Vehicle Identification Number (1): __________________________________________________________ Engine Serial Number (2):______________________________________________________________________ Key Number (on the key): ______________________________________________________________________...

  • Page 14: Safety

    Polaris. Polaris strongly encourages you and any family 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...
  • Page 15 Safety Training A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Con- sumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-3764.

  • Page 16: Equipment Modifications

    The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

  • Page 17: Safe Riding Gear

    Helmet Wearing a helmet can prevent a severe head injury. When- ever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S.

  • Page 18: Eye Protection

    Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 19: Safety Warnings

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

  • Page 20: Operating Without Instruction

    Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.

  • Page 21: Handling Gasoline

    Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is per- formed or where gasoline is stored.

  • Page 22: Protective Apparel

    Safety Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.

  • Page 23: Carrying A Passenger

    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 adversely affect operator judgment, reaction time, balance and perception.

  • Page 24: Operating On Pavement

    Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use.

  • Page 25: Physical Control Of The Atv

    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 Removing a hand from the handlebars or feet from the footpegs during operation can reduce your ability to control the vehicle or cause loss of...

  • Page 26: Turning Improperly

    Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

  • Page 27: Improper Hill Climbing

    Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 72. Operating on Steep Hills Operating on excessively steep hills could cause an overturn.

  • Page 28: Descending Hills Improperly

    Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special tech- nique is required when braking while traveling downhill. See page 78.

  • Page 29: Crossing Hillsides

    Safety Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual.
  • Page 30 Safety Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost Keep body weight uphill. Apply the front brakes gradually (right lever).
  • 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 and practiced the skills necessary to control the ATV on such terrain.

  • Page 32: Improper Tire Maintenance

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

  • Page 33: Skidding Or Sliding

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

  • Page 35: Poor Visibility

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

  • Page 36: Physical Skills

    Safety Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice. Never operate the ATV on a frozen body of water. Operating a Damaged ATV Operating a damaged ATV can result in an accident.

  • Page 37: Hot Exhaust Systems

    Safety Warnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
  • Page 38 If an informational or graphic label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. NOTICE: Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

  • Page 39: General Warning

    Safety Labels and Locations General Warning WARNING Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear. Never use on public roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: •...

  • Page 40: Age 16 Warning

    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 Discretionary/Sport ATV Warning WARNING •...

  • Page 41: Tire Pressure/Load Warning

    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. Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

  • Page 42: Features And Controls

    Features and Controls Main Key Switch Engine Stop Switch Start Button...

  • Page 43: Start Button

    Start Button Press the start button to engage the starter. Always release the start button promptly when the engine starts. If the starter fails to engage, replace the blown fuse or see your Polaris dealer. Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly.

  • Page 44: Indicator Lights

    • Hot engine • Reverse gear is selected • Neutral gear is selected If indicator lights fail to operate, check connections. See your Polaris dealer for inspection of the capacitor and voltage regulator.
  • Page 45 Features and Controls Lights Headlights Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights.

  • Page 46: Clutch Lever

    Features and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar. Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears. Adjusting Knob The clutch is self-adjusting, but lever position can be changed to fit the operator’s hand.

  • Page 47: Clutch Fluid

    Clutch Oil. Do not use brake fluid. Do not mix clutch fluid with any other hydraulic fluids. See page 172 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2. Turn the handlebar until the master cylinder is in a horizontal position.

  • Page 48: Throttle Lever

    Features and Controls Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
  • Page 49 Engine speed returns to idle when the lever is released. See page 141 for throttle adjustment procedures. This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick...

  • Page 50: Foot Brake

    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 the Foot Brake foot brake system.
  • Page 51 Features and Controls Hand Brake The hand brake operates the front brakes. The hand Hand Brake brake is located on the right handlebar. These brakes (Front Brake) are hydraulically activated disc type brakes. Squeeze the brake lever toward the handlebar to engage the front brakes.
  • 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 hygroscopic, meaning it rapidly absorbs moisture from the air.
  • Page 53 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 172 for the part numbers of Polaris prod- ucts.

  • Page 54: Parking Brake

    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.
  • 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.

  • Page 56: Shift Pedal

    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 to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released.

  • Page 57: Shifting Gears

    Manual Shift Shifting Gears Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral. 2. Squeeze and hold the brake lever. Do not apply throttle. 3. Squeeze the clutch lever to disengage the clutch.

  • Page 58: Reverse Lock-Out Switch

    Features and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse uninten- tionally. 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.
  • 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 speed decreases, disengage the clutch and shift to a lower gear. Be sure engine speed has sufficiently decreased before downshifting. WARNING! Improper use of the brakes or shifting when the engine speed is too high can cause the tires to lose traction or stop rotating, which could result in loss of control.

  • Page 60: Fuel Tank

    10 percent, such as E-85 fuel. Fuel Filter The fuel tank has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged.

  • Page 61: Fuel Valve

    Features and Controls Fuel Valve The fuel valve is located on the right side of the Fuel Valve 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.

  • Page 62: Operation

    Break-In Period The break-in period for your new Polaris ATV is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. No single action on your part is as impor- tant as following the procedures for a proper break-in.
  • Page 63 Break-In Period Perform the following break-in and maintenance procedures carefully. 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever han- dling gasoline. 2. Check the oil level. Add the recom- mended oil as needed to maintain the oil level in the proper range.

  • Page 64: Pre-Ride Inspection

    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. Brake systems / lever travel Brake fluid Clutch lever Clutch fluid...
  • Page 65 Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Verify operation, apply Polaris dielectric grease to the socket when the lamp is replaced Verify operation Wear helmet, goggles, protective clothing Check freeplay. If the tire moves excessively, do not operate.

  • Page 66: Safe Operation Practices

    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 dis- abilities to operate this vehicle.
  • Page 67 Safe Operation Practices 8. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the han- dlebars while operating, and always keep both feet on the footpegs. 9.
  • Page 68 Respect the environment in which you ride. Find out where the desig- nated riding areas are by contacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you repre- sent the sport and can set a good example (or a poor example) for others to follow.

  • Page 69: Trail Etiquette

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

  • Page 70: Starting The Engine

    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 lever while starting the engine.
  • Page 71 Repeat until the engine starts. If the engine does not start, review the engine troubleshooting information beginning on page 174. If all conditions are favorable and the engine still does not start, see your Polaris dealer for service.

  • Page 72: Driving Procedures

    Operation Driving Procedures 1. Wear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. See page 52. 5.

  • Page 73: Making Turns

    Operation Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turn- ing, and the inside tire slips traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footpeg.

  • Page 74: Driving On Slippery Surfaces

    Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slip- pery or loose terrain. 2. Slow down when entering slippery areas. 3.
  • 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 Sideways direction of skid skid...

  • Page 76: Driving Uphill

    Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25 ° 3. Always check the terrain carefully before ascending any hill.
  • Page 77 Driving Uphill 5. Keep both feet on the footpegs. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards. 8. Never back down a hill. WARNING! Aggressively applying the foot brake when backing down a hill may cause rear tipover.
  • Page 78 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.

  • Page 79: Turning Around On A Hill

    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.
  • Page 80 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 down- ward.
  • Page 81 Turning Around on a Hill 9. Pull in the clutch lever, shift into neutral and restart the engine. 10. Release the parking brake and slowly release the clutch lever, allowing the ATV to pro- ceed slowly. Stay in first gear, using the brakes for additional speed control if necessary, until more level ground is reached.

  • Page 82: Driving Downhill

    Operation Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25 ° 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control.

  • Page 83: Parking On A Hill Or Incline

    Operation Parking on a Hill or Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precau- tions: 1. Stop the engine. 2. Place the transmission in first gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.

  • Page 84: Driving Through Water

    Operation Driving Through Water Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions when operating through water: 1. Determine water depth and current before entering water. 2. Choose a crossing where the water level is lowest and where both banks have gradual inclines.
  • Page 85 Driving Through Water NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footpeg level. As soon as possible, perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 87. Engine oil and all grease fittings need special attention.

  • Page 86: Driving In Reverse

    Operation Driving in Reverse Follow these precautions when operat- ing in reverse: 1. Always check for obstacles or peo- ple behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stop- ping. 5. Avoid turning at sharp angles. 6.
  • Page 87 Operation Driving in Reverse 7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed. 8. Always look left, right and behind the ATV before backing. NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

  • Page 88: Driving Over Obstacles

    Operation Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before oper- ating 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.

  • Page 89: Emission Control Systems

    Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

  • Page 90: Exhaust Emission Control System

    The engine and related components must be main- tained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

  • Page 91: Maintenance

    Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. Record maintenance and service in the Maintenance Log beginning on page 201.

  • Page 92: Periodic Maintenance Chart

    Maintenance Periodic Maintenance Chart The recommended service intervals are based on average riding conditions. Vehicles sub- jected 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 •...

  • Page 93: Maintenance Chart Key

    Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often under severe use.
  • Page 94 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 Pre-ride Remarks Check each day before operating the vehicle.
  • Page 95 Engine mounting bolts Valve clearance Outer clutch cover 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 Maintenance Interval (whichever comes first) Hours Calendar...
  • Page 96 Maintenance Periodic Maintenance Chart Item Brake pad wear Battery Air filter Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Shift lever bolt Valve clearance Clutches Spark plug Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Monthly Monthly...
  • Page 97 Drive chain(s) Brake pad replacement Coolant strength 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 Maintenance Interval (whichever comes first) Hours Calendar...
  • Page 98 Maintenance Periodic Maintenance Chart Item Upper steering post (1) Front A-Arms (2) Rear axle/eccentric (3) Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Remarks Inspect; tighten fasteners; grease after washing ATV/driving in water Inspect; tighten fasteners; grease (also after washing ATV or driving in water)
  • Page 99 Cylinder and piston Piston pin circlip groove 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 Maintenance Interval (whichever comes first) Hours Calendar...
  • Page 100 Maintenance Periodic Maintenance Chart Item Compression ring Oil scraper ring Camshaft Valve spring cap Camshaft bearings Valve springs Valve seats/guides Rocker arm rollers Timing chain Cam chain tensioner Bearings (connecting rod, balance shaft, crankshaft main) Crankshaft run-out Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters)
  • Page 101 Front/rear wheel bearings Toe adjustment Headlight aim 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 Maintenance Interval (whichever comes first) Hours Calendar...
  • Page 102 Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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.

  • Page 103: Engine Oil Level

    Engine Oil Level Check the oil level before each use of the vehi- cle. 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 between the 1/2 and 3/4 levels in the sight glass.

  • Page 104: Engine Oil Change

    Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. 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. Always change both oil filters and clean the oil screens whenever changing oil.
  • Page 105 Engine Oil Change 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.
  • Page 106 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Oil Screen Plug Front Short Screen O-Rings View from bottom of vehicle...
  • Page 107 Maintenance Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine. 2. Remove the short oil screen. Clean the screen components thoroughly and blow well with low pressure compressed air. 3.
  • Page 108 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.
  • Page 109 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 in increased engine wear.
  • Page 110 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.
  • Page 111 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 40 oz. (1.2 liters) of the recommended engine oil (see page 98).

  • Page 112: Engine Cooling System

    Always follow the manufacturer's mixing recommendations for the freeze protection required in your area. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 172 for the part numbers of Polaris products.

  • Page 113: Coolant Level

    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 vis- ible at the bottom of the side panel, add 6 oz. (175 ml) of coolant.
  • Page 114 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 while the engine is warm or hot.

  • Page 115: Cooling System Bleeding

    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 pres- sure cap. 1. Remove the pressure cap. 2.

  • Page 116: Air Filter Systems

    Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover. 3. Remove the wing nuts securing the filter to the airbox. 4. Pull the filter assembly out of the air box. Note the placement of the rubber ring for rein- stallation.

  • Page 117: Idle Speed

    2. Start the engine and allow it to idle for five minutes, or until operating temperature is reached. 3. Turn the idle adjusting wheel (1) until idle speed reaches 1700-1800 RPM. If idle speed is unsatisfactory after per- forming this procedure, see your Polaris dealer for informa- tion about jetting changes. Maintenance...

  • Page 118: Carburetor Draining

    Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. Turn the fuel valve off. 2.

  • Page 119: Carburetor Jetting

    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 adjust- ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich.

  • Page 120: Headlight Adjustment

    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.
  • Page 121 Lights Headlight Adjustment 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.

  • Page 122: Headlight Lamp Replacement

    Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. 1.
  • Page 123 Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover. 2. Remove the wire harness connector from the headlight. 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 the headlamp with the retaining brackets.
  • Page 124 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.
  • Page 125 Rear Cab Removal 1. 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.

  • Page 126: 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. The spark Spark...
  • Page 127 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will 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.

  • Page 128: Spark Arrestor Clean-Out

    Maintenance Spark Arrestor Clean-Out WARNING Failure to heed the following warnings while servicing 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.
  • Page 129 Spark Arrestor Clean-Out To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 87. 1. Remove the retaining screw and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen.

  • Page 130: Vehicle Immersion

    Maintenance Vehicle Immersion If the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stops during or after operating in water, restarting WILL result in serious engine damage. Trans- port 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.
  • Page 131 Maintenance Vehicle Immersion 1. Turn the fuel valve off. 2. Drain water from the air box and clean the air filter. See page 112. 3. Drain the carburetor bowl. See page 114. 4. Remove the spark plug. See page 122. WARNING! Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts.
  • Page 132 Vehicle Immersion 6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride inspection level, water has entered the crankcase.
  • Page 133 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. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory.

  • Page 134: Battery Removal

    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 a full charge.

  • Page 135: Battery Installation

    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.
  • Page 136 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 battery could explode, causing severe injury or death.
  • Page 137 See your Polaris dealer for inspection of the voltage regulator and generator. When using an automatic charger such as the Polaris Battery Tender, refer to the manufac- turer's instructions for recharging. When using a constant current charger, use the guidelines...
  • Page 138 Maintenance Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Voltage Charge 100% 12.8-13.0 volts 75%-100% 12.5-12.8 volts 50%-75% 12.0-12.5 volts 25%-50% 11.5-12.0 volts 0%-25% 11.5 volts or less Action None, check at 3 months from date of manufacture May need slight charge, if no...

  • Page 139: Tire Tread Depth

    Maintenance Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires 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.

  • Page 140: Wheel Removal

    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. Stop the engine. Place the transmission in gear. Lock the parking brake.

  • Page 141: Wheel Installation

    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. Never install the rim with the valve stem to the inside of the vehicle.

  • Page 142: Clutch System Bleeding

    Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Maintenance Chart beginning on page 87. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system.
  • Page 143 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. Extract fluid from the master cylinder during the process to prevent overflowing.
  • Page 144 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 141. " 1/16 - 1/8" (1.5 - 3 mm)
  • Page 145 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 knowledgeable persons who perform this procedure must follow the adjustment procedures exactly.
  • Page 146 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 whenever the cover is loosened or removed.
  • Page 147 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.

  • Page 148: 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. 1. Position the vehicle on a level surface.
  • Page 149 The rear measurement should be between 0" and 1/16" (0-1.5 mm) more than the front mea- surement. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your Polaris dealer for service. Maintenance Stand String...

  • Page 150: Chain Tension Inspection

    Chain Tension Inspection Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain. NOTICE: Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result.
  • Page 151 Chain Tension Inspection 1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fas- ten the strap around the axle and rear bumper tube. 2. Tighten the strap until a straight line (2) can be drawn from the axle to the transmission output shaft, intersecting the swing arm pivot.
  • Page 152 Maintenance Chain Tension Adjustment 1. Loosen the two eccentric locking bolts. Refer to the illustration on the following page. 2. Insert a pin punch into the eccentric axle housing. 3. Roll the vehicle slightly to adjust chain slack to the proper dimension. 4.
  • Page 153 Maintenance Chain Tension Adjustment Step 2 Proper splicelink clip opening position Step 1...

  • Page 154: Handlebar Adjustment

    Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited 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.

  • Page 155: Steering Inspection

    Steering Inspection Check the steering assembly periodically for loose 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...

  • Page 156: Suspension Settings

    Maintenance Suspension Settings Use a flat-blade screwdriver to make damping adjustments. When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position. Rear Shock (Standard and Limited Edition) Setting Compression Damping Softest Factory Firmest Front Shock (Limited Edition) Setting...

  • Page 157: Front Suspension

    Maintenance Front Suspension Compression Damping (Limited Edition) To adjust the front suspension compression damping, use the adjustment procedures outlined for the rear suspension compression damping on page 157. Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator See page 154.

  • Page 158: Spring Preload

    WARNING! Uneven adjustment may cause poor handling of the ATV, which could result in an accident. Always adjust both the left and right spring preloads equally or have your Polaris dealer perform the adjustments. 4. Tighten the jam nut firmly against the adjuster ring.

  • Page 159: Rear Suspension

    Rear Suspension The rear suspension spring preload, 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.
  • Page 160 Maintenance Rear Suspension Rebound Damping Use a flat-blade screwdriver to make damping adjustments. The rebound damping is factory set at 16 clicks from fully closed. See Suspension Settings on page 152. 1. Locate the rebound damping clicker drum between the lower spring seat and the lower shock mount.

  • Page 161: Compression Damping

    Rear Suspension Compression Damping Use a flat-blade screwdriver to make damping adjust- ments. The factory setting is at 10 clicks from fully closed. See Suspension Settings on page 152. The compression damping clicker is located on top of the shock reservoir, under the right rear fender. 1.

  • Page 162: Washing The Vehicle

    Do not allow these types of products to contact the vehicle. 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.
  • Page 163 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. •...
  • Page 164 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. Avoid direct- ing the water stream at the following items: •...
  • Page 165 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 vehi- cle.

  • Page 166: Battery Storage

    Maintenance Storage NOTICE: 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 158. Battery Storage Refer to pages 129-134 for battery storage and battery charging procedures.
  • Page 167 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 100. 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.
  • Page 168 Stabilize the Fuel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc- tions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 169 Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 87. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3.

  • Page 170: Transporting The Atv

    Maintenance Transporting the ATV 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.
  • Page 171 Maintenance Transporting the ATV...

  • Page 172: Specifications

    Specifications Max. Weight Capacity 215 lbs./98 kg Dry Weight 360 lbs./163 kg Fuel Capacity 3.1 gal./11.8 l Overall Length 71.5 in./182 cm Overall Width 47 in./119 cm Overall Height 45 in./114 cm Wheelbase 50.5 in./128 cm Ground Clearance 5 in./13 cm Min.
  • Page 173 Driving System Type Rear Two-Wheel Drive Shift Type 5-Speed Manual Shift Primary Ratio 2.516 Gear Ratio - 1st 2.500 Gear Ratio - 2nd 1.941 Gear Ratio - 3rd 1.579 Gear Ratio - 4th 1.333 Gear Ratio - 5th 1.130 Gear Ratio - Reverse 2.429 OUTLAW 450 MXR Jetting Chart ALTITUDE...
  • Page 174 Max. Weight Capacity 215 lbs./98 kg Dry Weight 370 lbs./168 kg Fuel Capacity 3.1 gal./11.8 l Overall Length 71.5 in./182 cm Overall Width 47.5 in./121 cm Overall Height 45 in./114 cm Wheelbase 50.5 in./128 cm Ground Clearance 5 in./13 cm Min.
  • Page 175 Driving System Type Rear Two-Wheel Drive Shift Type 5-Speed Manual Shift Primary Ratio 2.516 Gear Ratio - 1st 2.500 Gear Ratio - 2nd 1.941 Gear Ratio - 3rd 1.579 Gear Ratio - 4th 1.333 Gear Ratio - 5th 1.130 Gear Ratio - Reverse 2.429 OUTLAW 525 S Jetting Chart ALTITUDE...

  • Page 176: Polaris Products

    Part Number Description 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz. cartridge) 2871460 Starter Drive Grease (2 oz.) 2871329...

  • Page 177: Polaris Products

    Part Number Description 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Brake Fluid (12 oz.) 2876335 Hydraulic Clutch Oil (qt.) Coolant Additives / Miscellaneous Polaris Products...

  • Page 178: 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 fuel Water is present in carburetor or fuel supply Fuel valve is turned off Engine is cold...
  • Page 179 Troubleshooting Solution Inspect, clean and/or replace spark plugs See your Polaris dealer Engage starter 2 times for 5 seconds each, then restart. If engine fails to start, inspect, clean and/or replace spark plugs. Recharge battery to 12.8 VDC...
  • Page 180 Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution See Polaris dealer for replacement Recharge battery to 12.8 VDC Check all connections and tighten Check all connections and tighten Solution...
  • Page 181 Mechanical failure Solution Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel Inspect system for leaks; see your Polaris dealer See your Polaris dealer See your Polaris dealer See your Polaris dealer...
  • Page 182 Kinked or plugged fuel vent line Old or non-recommended fuel Solution Inspect, clean and/or replace spark plug See your Polaris dealer Set gap to specs or replace plug Check all connections and tighten See your Polaris dealer Replace with new fuel Recharge battery to 12.8 VDC or replace...
  • Page 183 Electronic throttle control malfunction Incorrect idle adjustment Clogged idle jet Other mechanical failure Troubleshooting Solution Inspect and clean or replace See your Polaris dealer Adjust idle speed or see your Polaris dealer Disassemble carburetor and clean the jets See your Polaris dealer...
  • Page 184 Plugged, dirty or wet air filter Solution Add or change fuel, clean the fuel system Replace with recommended fuel Replace with recommended fuel See your Polaris dealer See your Polaris dealer Solution Inspect, clean and/or replace spark plugs Replace with recommended octane fuel...
  • Page 185 Excessive oil in system Use of non-recommended oil (too thin) Troubleshooting Solution Clean and/or replace needle valve Tighten jets See your Polaris dealer Solution Install a new hose Check oil level, maintain at recommended level Replace with a recommended oil...
  • Page 186 Solution Turn the fuel valve to reserve, refuel Clean fuel system and carburetor Inspect and clean or replace See your Polaris dealer See your Polaris dealer Clean radiator screen and core if equipped Clean engine exterior Check oil level, maintain at recommended level...
  • Page 187 Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery to 12.8 VDC...
  • Page 188 Operate at a faster speed to increase air flow Check oil level, maintain at recommended level Bleed the cooling system Drain and replace coolant with recommended coolant Shorten or replace hose See your Polaris dealer Replace fuse and check fan for proper operation or see your Polaris dealer...
  • Page 189 Faulty exhaust system Valve gap is too small Faulty ignition timing Troubleshooting Solution Clean fuel system and carburetor Replace the float Inspect and clean or replace Check system for damage; see your Polaris dealer Adjust valve gap See your Polaris dealer...

  • Page 190: 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 DIRECTIVES 98/37/EC as amended (Machinery Directive)
  • Page 191 PRODUCT IDENTIFICATION VEHICLE SERIES ___KA05__ OUTLAW 50 ___KA09__ OUTLAW 90 ___FA09__ SPORTSMAN 90 ___VA17__ RZR 170 ___PB20__ PHOENIX 200 ___BA32__ TRAIL BLAZER 330 ___CA32__ TRAIL BOSS 330 ___BA50__ SCRAMBLER 500 ___GJ45__ OUTLAW 450 ___GJ52__, ___GP52__ OUTLAW 525 ___LH27__ SPORTSMAN 300 ___LH46__ SPORTSMAN 400 ___MN50__...
  • Page 192 RANGER 800 6X6 ___HY__ RANGER HD 800 4X4 ___VH76__ RANGER RZR Authorized Signatory: __________________________________ Alexander A. Kennedy, Product Compliance Polaris Industries Inc., Engineering Operations 301 5th Avenue SW, Roseau, MN 56751 TRADE NAME MODEL YEARS 2008, 2009, 2010 2010 2009, 2010...

  • Page 193: Warranty

    Polaris dealer. REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
  • Page 194 LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war-...
  • Page 195 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES 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 repair. The following items are excluded from warranty coverage in the event of a warranty claim: •...
  • Page 196 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replace- ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR- RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 197 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 THIS WARRANTY. Some states do not allow limitations on how long an...
  • Page 198 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
  • Page 199 In the country where your vehicle was purchased: Warranty or Service Bulletin repairs 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.
  • Page 200 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 201 U.S.A. EPA Emissions Limited 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 conforms with applicable U.S.
  • Page 202 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 The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices •...
  • Page 203 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 LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 204 Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential vio- lation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 205: 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) 3 Hours (Break-in) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 206 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)
  • Page 207 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)
  • Page 208 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)

  • Page 209: Index

    Age Restrictions ....15 Air Filter Systems ... . 112 Battery Charging... . 132-134 Installation .
  • Page 210 Periodic Maintenance Chart . . . 87-97 Polaris Products ....172 Polishing ....161...
  • Page 211 Rebound Damping, Rear..156 Restrictions, Age....15 Reverse Lock-Out Switch ..54 Riding Area....64 Riding Gear.
  • Page 212 Index Spark Arrestor Clean-Out. . . 124-125 Spark Plugs....122-123 Spring Preload ....153 Spring Preload, Front .

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