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Polaris Outlaw 9921123 Owner's Manual

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  • Page 3 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 4 Visit us at www.polarisindustries.com...
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2006 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 6 Welcome Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles...
  • Page 7 Welcome We believe Polaris sets a standard of excellence for all utility and recreational vehicles man- ufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.

  • Page 8: Table Of Contents

    Specifications ....186 Polaris Products ... . 188 Troubleshooting... . . 190 Warranty .

  • Page 9: Know Your Vehicle

    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 10 Know Your Vehicle Vehicle Identification Numbers Vehicle Model Number: ____________________________________________________________________ Frame Vehicle Identification Number (1): ______________________________________________________ Engine Serial Number (2):__________________________________________________________________ Key Number (on the key): __________________________________________________________________...

  • Page 11: Safety Decals

    Age 16 Discretionary illegible or comes off, Warning Warning contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal. General Sport ATV Warning Warning...

  • Page 12: General Warning

    • avoid paved surfaces - pavement may seriously affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. 7172560...

  • Page 13: Age 16 Warning

    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 Sport ATV Warning WARNING This ATV may exceed the performance of other ATVs you may have ridden in the past.

  • Page 14: No Passenger Warning

    No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Tire Pressure Warning Tire Pressure/Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6) 7172566 REAR 4 (27.6)

  • Page 15: Safety

    Helmet Wearing a helmet can prevent a severe head injury. Whenever 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 16: Riding Gear

    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 17: Operator Safety

    Failure to follow the warnings 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 18: Safety Training

    You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis. If you purchased a used Polaris ATV, you can take the ATV RiderCourse ATV Enrollment Express at (800) 887-2887 available to or by visiting www.atvsafety.org.
  • Page 19 Safety Operator Safety 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, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
  • Page 20 Follow all operating procedures. • Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and age eli- gible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information...
  • Page 21 Safety Operator Safety • Never operate an ATV on a public street, road or highway, including a dirt or gravel road. • Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
  • Page 22 Do not turn at exces- sive speeds. • Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
  • Page 23 Operator Safety • Always follow proper procedures for crossing the side of a hill. Avoid hills with excessively slippery or loose sur- faces. Shift your weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.
  • Page 24 Operator Safety • Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of con- trol. • Always check for obstacles before oper- ating in a new area.
  • Page 25 FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer 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. • Never modify an ATV through improper installation or use of accessories.

  • Page 26: 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 27 HOW TO AVOID THE HAZARD 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 28 Safety Operator Safety WARNING POTENTIAL HAZARD Failure to follow the skill and experience recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV. HOW TO AVOID THE HAZARD Only operators with advanced skills and substantial experience should operate this ATV.
  • Page 29 Safety Operator Safety POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates this ATV. Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate an ATV safely and could be susceptible to accident or injury.
  • Page 30 Safety Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 31 Safety Operator Safety POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.
  • Page 32 Safety Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads.
  • Page 33 Safety Operator Safety POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.
  • Page 34 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.
  • Page 35 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds. WHAT CAN HAPPEN Excessive speed increases the operator's chance of losing control of the ATV, which can result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Always operate the ATV at a speed that's proper for the terrain, visibility and operating conditions, and your experience.
  • Page 36 Safety Operator Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving.
  • Page 37 Safety Operator Safety POTENTIAL HAZARD Towing or pulling an object behind the ATV. WHAT CAN HAPPEN A wagon, sled or other object towed behind an ATV does not have brakes or steering. The object may overturn or collide with other objects and cause serious injuries.
  • Page 38 Safety Operator Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain.
  • Page 39 Safety Operator Safety POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
  • Page 40 Operator Safety WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds.Never turn at excessive speed.
  • Page 41 Safety Operator Safety POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.
  • Page 42 Safety Operator Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper °...
  • Page 43 Operator Safety POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual beginning on page 82. Always check the terrain carefully before ascending any hill.
  • Page 44 Safety Operator Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill.
  • Page 45 Operator Safety POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual.
  • Page 46 Safety Operator Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill. Apply the front brakes gradually (right lever).
  • Page 47 Operator Safety WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
  • Page 48 Operator Safety WARNING POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator fall through the ice. HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water.
  • Page 49 Safety Operator Safety POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
  • Page 50 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...
  • Page 51 Safety Operator Safety WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death. WARNING Operating a damaged ATV can result in an accident with serious injury or death.
  • Page 52 Operator Safety WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious 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 53: Features And Controls

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

  • Page 54: Start Button

    Press the start button to engage the starter. Always release the start button promptly when the engine starts. NOTE: 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 55 • Hot engine • Reverse gear is selected • Neutral gear is selected NOTE: If indicator lights fail to oper- ate, check connections. See your Polaris dealer for inspec- tion of the capacitor and volt- age regulator. Reverse Hot Engine Neutral...
  • Page 56 Lights Headlights Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. This vehicle is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

  • Page 57: 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 58: Clutch Fluid

    Clutch Oil. Do not use brake fluid. Do not mix clutch fluid with any other hydraulic fluids. See page 188 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 59: Throttle Lever

    Features and Controls Throttle Lever Operating with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate the vehicle with an improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
  • Page 60 Throttle Lever This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open posi- tion when the operator releases the throttle lever, the engine will stop. The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety.

  • Page 61: 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.

  • Page 62: Hand Brake

    Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar. Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes. Always test brake lever travel and master cylin- der fluid level before riding.
  • Page 63 Features and Controls Master Cylinder/Brake Fluid Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation.

  • Page 64: Hand Brake Fluid Level

    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 188 for the part numbers of Polaris prod- ucts.

  • Page 65: 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 66 Parking Brake Important Safeguards • The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. • Always block the wheels on the downhill side of the ATV if leaving it parked on a hill.
  • Page 67 Features and Controls Manual Shift Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released.
  • Page 68 Manual Shift Shifting Gears NOTE: 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. NOTE: Do not squeeze the throttle lever. 3.

  • Page 69: 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 unintentionally. 1. Place the transmission in first gear. See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3.
  • Page 70 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 RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear. Improper use of the brakes, or shifting when the engine RPM is too high can cause the tires to lose traction or stop rotating, which could lead to loss of control, accident, and injury.

  • Page 71: Fuel Filter

    Polaris recommends the use of 91 octane or higher fuel. Do not use E-85 fuel. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean the fuel filter. See your Polaris dealer for service if you suspect the fuel filter is plugged.

  • Page 72: Fuel Valve

    Fuel Valve The fuel valve is located on the left side of the ATV. It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There's about a 5 to 8 mile (8 to 13 km) range on reserve gas.

  • Page 73: Break-In Period

    Careful treatment of a new engine and transmission will result in more efficient performance and longer life for both. The break-in period for your new Polaris ATV is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuel. Do not allow engine speed to exceed 7000 RPM during the break-in period.

  • Page 74: Pre-Ride Inspection

    1. Fill the fuel tank with gasoline. See page 74. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 109. 3. Allow the engine sufficient time to warm up before operating. 4.

  • Page 75: Pre-Ride Inspection

    If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Brake systems / lever travel Brake fluid Clutch lever Clutch fluid Suspension, front and rear Steering Frame nuts, bolts, fasteners...
  • Page 76 Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Check operation, apply Polaris dielectric grease to the socket when the lamp is replaced Check operation, adjust brake light switch Wear helmet, goggles, protective clothing Check freeplay. If the tire moves excessively, do not operate.

  • Page 77: Operation

    Fuel System 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 performed or where gasoline is stored.

  • Page 78: Starting The Engine

    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. NOTE: 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 79 Operation Starting the Engine 1. Shift the transmission to neutral. 2. Lock the parking brake. 3. Turn the fuel valve on. 4. Sit on the vehicle. 5. Disengage the clutch. 6. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine.
  • Page 80 NOTE: If the engine does not start, review the engine troubleshooting information beginning on page 190. If all conditions are favorable and the engine still does not start, see your Polaris dealer for service. 11. Push the choke knob completely in.

  • Page 81: Driving Procedure

    Operation Driving Procedure 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up. 3. Shift the transmission into gear. See page 64. 4. Check your surroundings and determine your path of travel.

  • Page 82: Making Turns

    Making Turns Practice making turns at slow speeds before attempting to turn at faster speeds. Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury or death. Avoid turning at sharp angles. Never turn at high speeds. Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times.

  • Page 83: Driving On Slippery Surfaces

    Operation Driving on Slippery Surfaces Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution, especially when downshifting.
  • Page 84 Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

  • Page 85: Driving Uphill

    Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25 Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual.
  • Page 86 Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (25 ° 3. Keep both feet on the footpegs. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening.

  • Page 87: Driving Across Hillsides

    Operation Driving Across Hillsides Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual. WARNING...
  • Page 88 Driving Across Hillsides If you enter into a situation where sidehilling is unavoidable, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keep- ing your feet on the footpegs. 3. Steer slightly into the hill to maintain direction.

  • Page 89: Turning Around On A Hill

    Operation Turning Around on a Hill Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25 and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary to turn around while climbing a hill is the K-turn: 1.
  • Page 90 Turning Around on a Hill 6. Reach across the handlebar and apply the front brakes to unlock the parking brake. 7. With the front brakes applied, pull in the clutch lever. Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

  • Page 91: Driving Downhill

    Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid in slowing.

  • Page 92: Parking On A Hill Or Incline

    Operation Parking on a Hill or Incline Avoid parking on a hill or incline if pos- sible. 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.

  • Page 93: Driving Through Water

    Operation Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs. Follow these proce- dures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual inclines.
  • Page 94 Driving Through Water Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in deeper water than recommended, it's critical to have it serviced as outlined in the mainte- nance chart beginning on page 97. Engine oil and all grease fittings need special attention. Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
  • Page 95 Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6.

  • Page 96: Driving In Reverse

    Follow the reverse operation procedures outlined in this manual. This Polaris ATV is equipped with a reverse speed limiter. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.

  • Page 97: Driving Over Obstacles

    Operation Driving Over Obstacles Be alert! Look ahead and learn to read the ter- rain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hang- ing branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

  • Page 98: 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 USDA Forest Service Standard 5100-1C. Federal law requires that this spark arres- tor be installed and functional when the vehicle is operated on public lands.

  • Page 99: Crankcase 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 100: Maintenance

    Maintenance Periodic Maintenance 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 procedures at the service intervals specified in your owner’s manual will void warranty coverage and decrease the performance and reliability of your vehicle.

  • Page 101: Periodic Maintenance Chart

    Periodic Maintenance Chart 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. NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 102 E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Have an authorized Polaris dealer perform these services. Use Polaris Premium All Season Grease or grease conforming to NLGI No. 2. WARNING could result in component failure and lead to...
  • Page 103 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 104 Idle speed Engine mounting bolts Valve clearance 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 105 Periodic Maintenance Chart Item Brake pad wear Battery Air filter Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Clutches Spark plug Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) Monthly Monthly Weekly 26 (100)
  • Page 106 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 107 Periodic Maintenance Chart Item Upper steering post (1) Front A-Arms (2) Rear Control Arm Bushings (3) Stabilizer Bar (4) Rear Control Arm Needle Bearings (5) Maintenance Interval (whichever comes first) Hours Calendar Fuel Used in gallons (liters) 12 M Remarks Inspect;...
  • Page 108 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 109 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 110 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 111 Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications.

  • Page 112: 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 at the upper edge of the sight glass.

  • Page 113: Engine Oil Change

    Engine Oil Change If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filters within a few hours of draining the oil.
  • Page 114 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 115 Maintenance Engine Oil Change Cleaning the Short Oil Screen Hex Plug Front Short Screen View from bottom of vehicle...
  • Page 116 Engine Oil Change Cleaning the Short Oil Screen 1. Insert a hex key into the plug at the bottom of the engine. See illustration on preceding page. 2. Using a hammer, tap lightly on the key a few times to loosen the seal. Remove the plug. 3.
  • Page 117 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 118 Engine Oil Change Cleaning the Long Oil Screen An improperly installed oil screen will function poorly and result in increased engine wear. Install the screen securely at the angle shown in the illustration. 5. Insert the tool through the opening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible.
  • Page 119 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 120 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 108).

  • Page 121: Engine Cooling System

    See page 188 for the part numbers of Polaris products. NOTE: Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. NOTE: Always follow the manufacturer's mixing recommendations for the freeze protection required...

  • Page 122: Coolant Level

    Engine Cooling System Coolant Level The recovery bottle is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL and ADD marks on the side panel (when the fluid is cool). As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the...
  • Page 123 Engine Cooling System Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level If the recovery bottle has run dry, inspect the level in the radiator and add coolant if necessary.

  • Page 124: 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 125 Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover. 3. Loosen the filter clamp. 4. Remove the air filter. 5. Remove the inner and outer foam filter elements from the internal cage. Foam Filter Element Retaining...
  • Page 126 Maintenance Air Filter Systems 6. Wash the filters in soapy water, then rinse and let dry. 7. Apply a commercially available foam filter lubricant to the foam filters. 8. Reinstall all components. 9. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

  • Page 127: Idle Speed

    3. Start the engine and allow it to idle for five min- utes, or until operating temperature is reached. 4. Turn the idle adjusting wheel (1) until idle speed reaches 1500-1600 RPM. NOTE: If idle speed is unsatisfactory after performing this procedure, see your Polaris dealer for information about jetting changes.

  • Page 128: Carburetor Draining

    Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Always drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. Turn the fuel valve off. 2.

  • Page 129: 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 130 Lights When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation.

  • Page 131: Headlight Adjustment

    Lights Headlight Adjustment 1. Position the vehicle on a level surface with the head- light 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 132 Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb.
  • Page 133 Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see page 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp.
  • Page 134 Lights Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboard pivot pin of the headlamp. Adjust for approximately 1/16" clearance between the bracket and the edge of the headlight. Tighten the mounting screws. IMPORTANT: Be sure the bracket is 90 degrees to the pivot pin so the lamp can move freely.

  • Page 135: Brake Light Adjustment

    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 immedi- ately flash on and off with each movement of the brake pedal.
  • Page 136 Front Cab Removal 1. Remove the left and right cab mount screws (1). 2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2). 4. Remove the four side panel screws (3). 5.

  • Page 137: Side Panel Removal

    Maintenance Side Panel Removal 1. Unlatch and remove the seat. 2. Remove the front cab. Side Panel 3. Remove the two screws securing the side panel. Screws 4. Remove the side panel.
  • Page 138 Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts (2), washers and grommets (3) on the top of the cab. 4. Remove the cab. Maintenance...

  • Page 139: Spark Plugs

    Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
  • Page 140 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. NOTE: The tip should not be white.
  • Page 141 Maintenance Spark Plugs Spark Plug Removal 1. Access the spark plug at the right side of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft.
  • Page 142 Spark Arrestor Clean-Out To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 97. Failure to heed these warnings could result in serious injury or death. Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot.
  • Page 143 Spark Arrestor Clean-Out Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the three screws (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components are warm.
  • Page 144 Maintenance Spark Arrestor Clean-Out 3. Inspect the screen for wear and damage. Replace a worn or damaged screen. 4. Remove and inspect the gasket (4). Replace a worn or damaged gasket. 5. Reinstall the gasket and arrestor. Torque screws to 50 in. lbs. (5.6 Nm).

  • Page 145: Vehicle Immersion

    Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it's critical to dry it promptly and properly before starting the engine. Do not start the engine after an ATV has been in water that exceeds the recommended depth. Serious engine damage WILL occur.
  • Page 146 Vehicle Immersion 1. Turn the fuel valve off. 2. Drain water from the air box and clean the air filter. See page 122. 3. Drain the carburetor bowl. See page 125. 4. Remove the spark plug. See page 138. Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts.
  • Page 147 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 148 Battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.

  • Page 149: 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 150: Battery Installation

    Battery Installation NOTE: Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger. 1.
  • Page 151 NOTE: If the battery fails to recharge during vehicle operation, check voltage regulator connec- tions. See your Polaris dealer for inspection of the voltage regulator and generator. Charging Terminal...
  • Page 152 Battery Charging (Sealed Battery) 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 on the following page for recharging. An overheated battery could explode, causing severe injury or death. Always watch charging times carefully.
  • Page 153 Maintenance Battery Charging (Sealed Battery) NOTE: 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...

  • Page 154: Tire Tread Depth

    Tires 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. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires.

  • Page 155: 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 156: Wheel Installation

    Wheel Installation Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Never install the rim with the valve stem to the inside of the vehicle. Always ensure that all nuts are torqued to specification. 1.

  • Page 157: Boot Inspection

    Boot Inspection 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...

  • Page 158: Boot Burping

    Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape (2).

  • Page 159: 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 97. Always bleed the clutch system any time the clutch lever feels unresponsive. Always use the recommended fluid when bleeding the clutch system.
  • Page 160 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. NOTE: Extract fluid from the master cylinder during the process to prevent overflowing. 6.
  • Page 161 Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are needed, use the procedure on page 159. " 1/16 - 1/8" (1.5 - 3 mm)
  • Page 162 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 163 Maintenance Brakes An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill. Both brakes are self-adjusting, but the following checks are recommended to keep the brake systems in good operating condition.
  • Page 164 Brakes 1. Always maintain brake fluid at the recommended level. See pages 60-61. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5.

  • Page 165: Toe Alignment

    Toe Alignment Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting.
  • Page 166 (3) and rear (4) of the front rim. The difference between these two measure- ments should be between 0" and 1/16" (0-1.5 mm) toe out. NOTE: If you discover improper alignment, see your Polaris dealer for service. Maintenance String Stands...

  • Page 167: Chain Tension

    Maintenance Chain Tension 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. Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain.

  • Page 168: Chain Tension

    Maintenance Chain Tension 1. Loosen the upper and lower pivot mounting bolts (1). 2. Thread the chain adjusting bolt (2) inward or outward to adjust chain slack to the proper dimension. 3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4.

  • Page 169: 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 and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service.

  • Page 170: 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 171: Front Suspension

    Maintenance Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. Stop the engine. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.
  • Page 172 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.

  • Page 173: Spring Preload

    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 and right spring preloads equally or have your Polaris dealer perform the adjustments. WARNING...
  • Page 174 Front Suspension Spring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring clockwise to increase preload (1). Turn the ring counter-clockwise to decrease preload (2). Adjusting Ring...

  • Page 175: Rear Suspension

    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 plac- ing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound.
  • Page 176 Rear Suspension Suspension Set-Up 5. Remove the stand and have a rider sit comfortably on the seat with hands on the handle- bars. 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.
  • Page 177 Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the soft- est position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments. Rear Shock Setting Softest Factory...
  • Page 178 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 179: Compression Damping

    Rear Suspension Compression Damping The compression damping clickers are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From this position, turn the screw clockwise to increase com- pression damping.
  • Page 180 Keeping your vehicle clean will not only improve its appearance but it can also extend the life of various components. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.
  • Page 181 Cleaning Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 182 • Transmission seals NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
  • Page 183 Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehi- cle.
  • Page 184 Storage Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Exterior Make necessary repairs and clean the vehicle as recommended. See page 177. Battery Storage Refer to pages 145-150 for battery storage and battery charging procedures.
  • Page 185 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 110. Air Filter / Air Box Inspect and clean (or replace) the air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels.
  • Page 186 Storage 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. NOTE: Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
  • Page 187 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3.
  • Page 188 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.

  • Page 189: Specifications

    Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System See your owner’s manual supplement or your Polaris dealer 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E 0.6 mm / .024 in.

  • Page 190: Jetting Chart

    Gear Ratio - 5th 1.130 Gear Ratio - Reverse 2.429 Jetting Chart Please see your owner’s manual supplement or your Polaris dealer for jetting information. Outlaw 525 Tire Size - Front Tire Size - Rear Tire Pressure - All Front Brake...

  • Page 191: Polaris Products

    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.
  • Page 192 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.) 2872893 Engine Degreaser (12 oz.) Coolant Additives / Miscellaneous Polaris Products...

  • Page 193: Troubleshooting

    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 194 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 195 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 196 Mechanical failure Troubleshooting 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 197 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 198 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 199 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 200 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 201 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 See your Polaris dealer...
  • Page 202 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 203 Operate at a faster speed to increase air flow 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 204 Faulty exhaust system Valve gap is too small Faulty ignition timing 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 205: 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 206 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 207 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 208 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 209 LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's war- ranty or service bulletin coverage if you have any questions.
  • Page 210 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 211 EXPORTED VEHICLES How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce- dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
  • Page 212 Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
  • Page 213 Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.

  • Page 214: Maintenance Log

    Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE SERVICE INTERVAL (HOURS) 3 Hours (Break-in) TECHNICIAN SERVICE PERFORMED / COMMENTS...
  • Page 215 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)
  • Page 216 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)
  • Page 217 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL (HOURS)

  • Page 218: Index

    Age Restrictions ....14 Air Filter Systems ..122-123 Arrestor, Spark ... 140-141 Battery Charging.
  • Page 219 Periodic Maintenance Chart . . 97-107 Polaris Products ....188 Polishing ....180...
  • Page 220 Restrictions ....14 Reverse Lock-Out Switch ..66 Riding Gear....12-13 Safety Decals Age 16 Warning.

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2007 outlaw 525

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