2009 Polaris Outlaw 525 IRS Problems and Repair Information
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Popular 2009 Polaris Outlaw 525 IRS Manual Pages
Owners Manual - Page 3
WARNING
The engine exhaust from this card, or if it has been removed, please call 1-800-342-3764 for assistance. A card containing important ATV safety information should be attached to cause cancer, birth defects or other reproductive harm. If you cannot locate this product contains chemicals known to the State of California to the owner's manual on the next page.
Owners Manual - Page 7
... Polaris Service Manual and should be sure to follow the instructions and recommendations in our Pure Polaris products, available through our online store at www.purepolaris.com. Many years of experience have gone into the engineering, design, and development of excellence for minor maintenance, but information about major repairs is interested in your vehicle, be performed...
Owners Manual - Page 11
...key number) and mating it in a safe place. Introduction
Service Requirements
The high performance engine in your vehicle requires routine service 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.
Please read and follow the "Break-In Period" and "Maintenance...
Owners Manual - Page 27
...vehicle to lean sharply to one side. Safety
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 forward gear. See page 75. • Always descend a hill with the transmission.... Do not descend a hill with the transmission in the owner's manual.
Owners Manual - Page 29
... uphill. Turn the ATV around and remount, following the procedure described in the owner's manual. Safety
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperly dismounting while... lock the parking brake. If all forward speed is pointed straight uphill. Never apply engine power. See page 76.
26 Apply the front brake slowly. Always maintain a steady speed...
Owners Manual - Page 32
... parts and accessories added to the vehicle must be installed and used according to reduce the chance of control or overturn (if tires regain traction unexpectedly).
If unavoidable, use of control or overturn. Operating Over Obstacles
Improperly operating over large obstacles such as ice, travel slowly and use on this manual.
or equivalent components...
Owners Manual - Page 55
Features and Controls
Manual Shift
Shift Pedal The gear shift pedal is located in the shifting sequence. To upshift to a higher ...your boot under the gear shift pedal and raise the pedal one full stroke. One full stroke of the pedal shifts the transmission to a horizontal position when released.
See page 53. The pedal automatically returns to the next gear in front of your foot...
Owners Manual - Page 56
...vehicle overturn. Repeat this procedure to progressively upshift to disengage the clutch. 4. As engine speed (RPM) increases in neutral. 2. WARNING! Do not apply throttle. 3. Depress the gear shift pedal one full stroke. When starting from a stopped position, place the transmission... and Controls
Manual Shift
Shifting Gears Always allow a cold engine to shift into first gear. 5.
Owners Manual - Page 57
...-out switch prevents the operator from shifting into reverse gear. See page 52. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3.
The switch must be manually unlocked before shifting into reverse unintentionally. Lock-Out Lever
54 Shift down into reverse gear.
Owners Manual - Page 58
Features and Controls
Manual Shift
Deceleration To slow or stop rotating, which could result in loss of the brakes or shifting when the engine speed is too high can cause the tires to lose traction or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. Improper use of control. As...
Owners Manual - Page 59
... on page 66 for service if you suspect the fuel filters are plugged.
56 Polaris recommends the use E-85 fuel. Do not use of the carburetor. Refer to clean the fuel filters.
See your Polaris dealer for correct choke and throttle settings during starting. Do not attempt to the engine starting a cold engine. The choke knob...
Owners Manual - Page 61
... of a new engine and transmission will result in more efficient performance and longer life for your part is the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of...in period with an additional 12 hours of cautious operation, with engine speed below 75% of this owner's manual. Do not allow engine speed to exceed 7000 RPM during the break-in the safety ...
Owners Manual - Page 92
Make adjustments as needed. Perform these procedures more often for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease
89
Post-ride Break-in gallons (liters)
Remarks
Fuel Used ------5 (20)
See Page 60
Check each day before operating the vehicle. adjust
139 98 100 112 --- See...
Owners Manual - Page 98
... Calendar --in gallons (liters)
Remarks
Fuel Used 156 (600) 156 (600) ------- See Page
12 M 12 M 24 M 24 M 36 M 36 M As required As required
Measure spring; adjust as needed Bleed as needed ; replace as needed Check entire transmission/bearings for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these procedures more...
Owners Manual - Page 127
... injury or death. Do not perform service on the spark arrestor while the system is hot. Wear eye protection and leather work gloves. Never go under the vehicle while it's inclined.
124 Maintenance
Spark Arrestor Clean-Out
WARNING
Failure to cool sufficiently before proceeding. Never run the engine in front of the vehicle while purging.
Owners Manual - Page 156
....
153 With the rider still on the suspension. 7. Subtract the step 8 measurement from the step 4 measurement. 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 vehicle, repeat the measurement performed in step 4. Maintenance
Front Suspension
Suspension Set-Up 6.
Owners Manual - Page 160
...8 measurement from the step 4 measurement. 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...4.25 inches (10.8 cm), decrease the rear spring preload on the handlebars. 6. Place the transmission in step 4. 9. Maintenance
Rear Suspension
Suspension Set-Up 5. Turn the handlebars fully to the ...
Owners Manual - Page 184
...Engine Stops or Loses Power
Possible Cause
Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or defective spark plug Worn or defective spark plug wire Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Old or non-recommended fuel...
Solution
Inspect and replace Replace with new fuel Inspect, clean and/or...
Owners Manual - Page 190
... you specific legal rights, and you may cause engine damage. Polaris suggests that the spark arrestor in accordance with your dealer require any of the above terms are in this vehicle will contact the appropriate personnel at least 1000 hours when subjected to state. Should your dealer to resolve any Polaris Servicing Dealer to perform warranty service...
Owners Manual - Page 196
Maintenance Log
Present this section of maintenance and services performed. This will provide you and future owners with an accurate log of your manual to your dealer each time your vehicle is serviced. DATE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS
3 Hours (Break-in)
15
30
45
193
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