Owners Manual
Page 5
... constant improvements in part, is based on the latest product information at the time of Polaris Industries Inc. Copyright 2008 Polaris Sales Inc. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Outlaw 525 IRS ATV Owner's Manual P/N 9922079 2 Printed in this publication are registered trademarks of publication.
... constant improvements in part, is based on the latest product information at the time of Polaris Industries Inc. Copyright 2008 Polaris Sales Inc. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Outlaw 525 IRS ATV Owner's Manual P/N 9922079 2 Printed in this publication are registered trademarks of publication.
Owners Manual
Page 56
... loss of control or vehicle overturn. When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke to warm up before shifting gears. 1. Gradually squeeze the throttle lever while slowly releasing the clutch lever. 7. As engine speed (RPM) increases in neutral. 2. Features and Controls Manual Shift Shifting Gears Always allow a cold engine to shift into first gear. 5. Release the brake lever...
... loss of control or vehicle overturn. When starting from a stopped position, place the transmission in first gear, simultaneously release the throttle, disengage the clutch and shift to second gear by raising the gear shift pedal one full stroke to warm up before shifting gears. 1. Gradually squeeze the throttle lever while slowly releasing the clutch lever. 7. As engine speed (RPM) increases in neutral. 2. Features and Controls Manual Shift Shifting Gears Always allow a cold engine to shift into first gear. 5. Release the brake lever...
Owners Manual
Page 64
Operation Pre-Ride Inspection Pre-Ride Checklist Coolant (if applicable) Coolant hoses (if applicable) Throttle Indicator lights / switches Engine stop switch Air filter Air box sediment tubes Headlamp Brake light / tail lamp Riding gear A-arm ball joints Rear shaft assembly Ensure proper level Inspect for tears, punctures and grease leaks Page 107 -44 40, 41 39 110 -117 119 13 -138 61 See your Polaris dealer. If the tire moves excessively, do not operate...
Operation Pre-Ride Inspection Pre-Ride Checklist Coolant (if applicable) Coolant hoses (if applicable) Throttle Indicator lights / switches Engine stop switch Air filter Air box sediment tubes Headlamp Brake light / tail lamp Riding gear A-arm ball joints Rear shaft assembly Ensure proper level Inspect for tears, punctures and grease leaks Page 107 -44 40, 41 39 110 -117 119 13 -138 61 See your Polaris dealer. If the tire moves excessively, do not operate...
Owners Manual
Page 80
..., release the clutch lever and lock the parking brake. Remount from the uphill side, keeping body 8 ft. (2.4 m) weight uphill. 9. Follow proper procedures for additional speed control if necessary, until it's pointing across the hill or slightly downward. 8. Pull in first gear, using the brakes for driving downhill. Stay in the clutch lever, shift into neutral and restart the engine. 10. Use the brakes to slowly allow the vehicle...
..., release the clutch lever and lock the parking brake. Remount from the uphill side, keeping body 8 ft. (2.4 m) weight uphill. 9. Follow proper procedures for additional speed control if necessary, until it's pointing across the hill or slightly downward. 8. Pull in first gear, using the brakes for driving downhill. Stay in the clutch lever, shift into neutral and restart the engine. 10. Use the brakes to slowly allow the vehicle...
Owners Manual
Page 92
... Polaris Premium All Season Grease 89 adjust 139 98 100 112 --- Make adjustments as needed. Post-ride Break-in gallons (liters) Remarks Fuel Used ------5 (20) See Page 60 Check each day before operating the vehicle. Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Boots Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve...
... Polaris Premium All Season Grease 89 adjust 139 98 100 112 --- Make adjustments as needed. Post-ride Break-in gallons (liters) Remarks Fuel Used ------5 (20) See Page 60 Check each day before operating the vehicle. Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Boots Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve...
Owners Manual
Page 96
...; X QE E Check spring length (see dealer) Check ratchet teeth for leaks at tank cap, lines, fuel valve, filter, carburetor; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling system hoses Radiator Fuel system Cylinder and piston Piston pin circlip groove X E Q z 60 60 90 90 90 90 90 90 Calendar 12 M 12 M 12 M 12 M 12 M 12 M --in gallons (liters) Remarks Fuel Used 104...
...; X QE E Check spring length (see dealer) Check ratchet teeth for leaks at tank cap, lines, fuel valve, filter, carburetor; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Clutch springs Cam chain tensioner Coolant system Cooling system hoses Radiator Fuel system Cylinder and piston Piston pin circlip groove X E Q z 60 60 90 90 90 90 90 90 Calendar 12 M 12 M 12 M 12 M 12 M 12 M --in gallons (liters) Remarks Fuel Used 104...
Owners Manual
Page 98
... Perform these services Use Polaris Premium All Season Grease 95 replace as needed Inspect periodically; change yearly 140 Replace Replace Clean out 124 Inspect; adjust when 146 parts are replaced Adjust as needed; adjust as needed Bleed as needed Inspect; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid Jet needle/needle jet Brake fluid Spark arrestor Front/rear wheel bearings Toe adjustment Headlight...
... Perform these services Use Polaris Premium All Season Grease 95 replace as needed Inspect periodically; change yearly 140 Replace Replace Clean out 124 Inspect; adjust when 146 parts are replaced Adjust as needed; adjust as needed Bleed as needed Inspect; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid Jet needle/needle jet Brake fluid Spark arrestor Front/rear wheel bearings Toe adjustment Headlight...
Owners Manual
Page 118
Maintenance Lights Headlight Adjustment 1. Position the vehicle on the wall at the same height. 3. Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 115 Start the engine and turn the headlight switch to the center of the headlight and make a mark on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2.
Maintenance Lights Headlight Adjustment 1. Position the vehicle on the wall at the same height. 3. Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 115 Start the engine and turn the headlight switch to the center of the headlight and make a mark on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2.
Owners Manual
Page 119
lbs. (3 Nm). Loosen the pivot screw and adjust the beam to 27 in. Observe the headlight aim on the wall. Tighten the screw and torque to the desired position. 6. Pivot Screw 116 The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Maintenance Lights 4. Include rider weight on the seat when measuring. 5.
lbs. (3 Nm). Loosen the pivot screw and adjust the beam to 27 in. Observe the headlight aim on the wall. Tighten the screw and torque to the desired position. 6. Pivot Screw 116 The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the wall. Maintenance Lights 4. Include rider weight on the seat when measuring. 5.
Owners Manual
Page 120
Allow lamps to skin. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. Grasp the bulb housing and turn it with bare fingers. If fingers do touch a lamp, clean it counterclockwise to remove the bulb. Hot components can cause burns to cool before servicing. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot...
Allow lamps to skin. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with denatured alcohol. 1. Grasp the bulb housing and turn it with bare fingers. If fingers do touch a lamp, clean it counterclockwise to remove the bulb. Hot components can cause burns to cool before servicing. 3. Remove the wire harness connector from your skin leaves a residue, causing a hot...
Owners Manual
Page 121
Remove the wire harness connector from the headlights. 3. Adjust the lamp as needed (see page 115), then tighten the adjuster screw. 118 Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Connect the wire harness to the headlamp. Remove the headlamp. 5. Reinstall the front cover. 8.
Remove the wire harness connector from the headlights. 3. Adjust the lamp as needed (see page 115), then tighten the adjuster screw. 118 Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Maintenance Lights Headlight Assembly Replacement 1. Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Connect the wire harness to the headlamp. Remove the headlamp. 5. Reinstall the front cover. 8.
Owners Manual
Page 122
Turn the ignition key on the brake pedal. 4. A properly operating rear brake light will immediately flash on the spring. If the light does not operate properly, grasp the switch body with each use of the brake pedal. 3. Lightly apply and release the foot brake several times. Recheck and readjust as needed until the brake light operates properly. 119 Switch Body Adjustment Nut Spring TIP: Rotate the adjusting nut counter-clockwise to increase...
Turn the ignition key on the brake pedal. 4. A properly operating rear brake light will immediately flash on the spring. If the light does not operate properly, grasp the switch body with each use of the brake pedal. 3. Lightly apply and release the foot brake several times. Recheck and readjust as needed until the brake light operates properly. 119 Switch Body Adjustment Nut Spring TIP: Rotate the adjusting nut counter-clockwise to increase...
Owners Manual
Page 156
... and 4 inches (9.5-10.2 cm). 9. Maintenance Front Suspension Suspension Set-Up 6. With the rider still on the vehicle, repeat the measurement performed 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. If the number is less than 4 inches (10.2 cm), increase spring preload and repeat all steps...
... and 4 inches (9.5-10.2 cm). 9. Maintenance Front Suspension Suspension Set-Up 6. With the rider still on the vehicle, repeat the measurement performed 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. If the number is less than 4 inches (10.2 cm), increase spring preload and repeat all steps...
Owners Manual
Page 160
... seat with hands on the suspension. 7. With the rider still on the vehicle, repeat the measurement performed in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the handlebars. 6. If the number is less than 4.5 inches (11.4 cm), increase spring preload and repeat all steps. Place the transmission...
... seat with hands on the suspension. 7. With the rider still on the vehicle, repeat the measurement performed in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the handlebars. 6. If the number is less than 4.5 inches (11.4 cm), increase spring preload and repeat all steps. Place the transmission...
Owners Manual
Page 171
Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./97.5 kg 389 lbs./176 kg...Air Jet Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System 45 148 OBDVS #4 100 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm CDI 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E 0.6 mm / .024 in. Dry Sump/Internal Reservoir 168 Specifications Outlaw 525 IRS...
Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./97.5 kg 389 lbs./176 kg...Air Jet Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System 45 148 OBDVS #4 100 200 w @ 3000 RPM 11:1 Electric Keihin FCR-MX 39mm CDI 25° +/- 3° @ 3500 RPM in neutral NGK DCPR8E 0.6 mm / .024 in. Dry Sump/Internal Reservoir 168 Specifications Outlaw 525 IRS...
Owners Manual
Page 172
...Specifications Outlaw 525 IRS Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio - Front Tire Size - Reverse Rear Two-Wheel Drive 5-Speed Manual Shift 2.516 2.500 1.941 1.579 1.333 1.130 2.429 Tire Size - All Front Brake Rear Brake Parking Brake Headlights Taillights Brakelight 21 x 7R10 20 x 10R10 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel...176;C and above) Main Jet: 148 Needle Clip Position: #4 Main Jet: 138 Needle Clip Position: #3 169 Rear Tire Pressure -
...Specifications Outlaw 525 IRS Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio - Front Tire Size - Reverse Rear Two-Wheel Drive 5-Speed Manual Shift 2.516 2.500 1.941 1.579 1.333 1.130 2.429 Tire Size - All Front Brake Rear Brake Parking Brake Headlights Taillights Brakelight 21 x 7R10 20 x 10R10 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel...176;C and above) Main Jet: 148 Needle Clip Position: #4 Main Jet: 138 Needle Clip Position: #3 169 Rear Tire Pressure -
Owners Manual
Page 190
... AND FROM THE DEALER IS YOUR RESPONSIBILITY). however, you may cause engine damage. When requesting warranty service you use of non-recommended lubricants may not be covered by warranty. Engine Oil 1. We recommend the use any warranty issues. Spark Arrestor Polaris warrants that you must take it to a Polaris dealer authorized to repair Polaris ATVs. Mixing oil brands or using non-recommended oil may use of Polaris engine oil. 2.
... AND FROM THE DEALER IS YOUR RESPONSIBILITY). however, you may cause engine damage. When requesting warranty service you use of non-recommended lubricants may not be covered by warranty. Engine Oil 1. We recommend the use any warranty issues. Spark Arrestor Polaris warrants that you must take it to a Polaris dealer authorized to repair Polaris ATVs. Mixing oil brands or using non-recommended oil may use of Polaris engine oil. 2.
Owners Manual
Page 192
... required to obtain documentation from Polaris Industries in your vehicle to perform the warranty repair. Upon residence verification, the servicing dealer will be done by an authorized Polaris dealer. You may be required to present documentation of your move or are traveling temporarily outside the country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo...
... required to obtain documentation from Polaris Industries in your vehicle to perform the warranty repair. Upon residence verification, the servicing dealer will be done by an authorized Polaris dealer. You may be required to present documentation of your move or are traveling temporarily outside the country where your vehicle was purchased: Warranty or Service Bulletin repairs must show the dealer photo...
Owners Manual
Page 203
... Panel Removal ...120 Sidehilling ...74 Signal words...6 Spark Arrestor Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...154 Spring Preload, Front ...155 Spring Preload, Rear ...158 Starting the Engine ...66-67 Steering Inspection ...151 Storage ...163-166 Suspension Front ...152-155 Rear ...156-159 Set-Up ...152-157 S Switches Engine Stop Switch ...Main Key Switch ...Reverse Lock-Out Switch ...Start Button ... S 39 39 54 39 Vehicle Identification Numbers ...8 Vehicle Immersion ...126-128 Warranty...
... Panel Removal ...120 Sidehilling ...74 Signal words...6 Spark Arrestor Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...154 Spring Preload, Front ...155 Spring Preload, Rear ...158 Starting the Engine ...66-67 Steering Inspection ...151 Storage ...163-166 Suspension Front ...152-155 Rear ...156-159 Set-Up ...152-157 S Switches Engine Stop Switch ...Main Key Switch ...Reverse Lock-Out Switch ...Start Button ... S 39 39 54 39 Vehicle Identification Numbers ...8 Vehicle Immersion ...126-128 Warranty...