Owners Manual
Page 4
... or the conditions on hills and rough terrain and in turns. Improper ATV use proper riding techniques to avoid vehicle overturns on public roads - avoid paved surfaces - pavement may seriously affect handling and control READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE...
... or the conditions on hills and rough terrain and in turns. Improper ATV use proper riding techniques to avoid vehicle overturns on public roads - avoid paved surfaces - pavement may seriously affect handling and control READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. passengers affect balance and steering and increase risk of losing control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE...
Owners Manual
Page 6
... this publication is expressly prohibited. Any reprinting or reuse of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. Printed in this publication are registered trademarks of the depictions and/or procedures contained within this publication. POLARIS, THE WAY OUT and OUTLAW are intended for omissions or inaccuracies. Depictions and/or procedures in U.S.A. 2010 OUTLAW 450 MXR/525 S ATV Owner's Manual P/N 9922479 2
... this publication is expressly prohibited. Any reprinting or reuse of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. Printed in this publication are registered trademarks of the depictions and/or procedures contained within this publication. POLARIS, THE WAY OUT and OUTLAW are intended for omissions or inaccuracies. Depictions and/or procedures in U.S.A. 2010 OUTLAW 450 MXR/525 S ATV Owner's Manual P/N 9922479 2
Owners Manual
Page 35
... cause changes in conditions of control or an accident. Never exceed the stated load capacity for this ATV. Clean headlights frequently and replace burned out headlamps promptly. Never haul cargo or tow a load with this ATV. 31 Operate this vehicle off-road only. Improper Cargo Loading Overloading the ATV or carrying/towing cargo may overturn or collide with highway-approved lights. Safety Safety Warnings...
... cause changes in conditions of control or an accident. Never exceed the stated load capacity for this ATV. Clean headlights frequently and replace burned out headlamps promptly. Never haul cargo or tow a load with this ATV. 31 Operate this vehicle off-road only. Improper Cargo Loading Overloading the ATV or carrying/towing cargo may overturn or collide with highway-approved lights. Safety Safety Warnings...
Owners Manual
Page 49
... lever, the engine will stop, and power to increase engine speed and vehicle movement. Features and Controls Throttle Lever The throttle lever is applied. Do not squeeze the throttle lever while starting the engine. Fuel is injected into the intake passage each time throttle is located on the right handlebar. See page 141 for throttle adjustment procedures. Do not squeeze the throttle lever when the engine is released. Engine speed returns to...
... lever, the engine will stop, and power to increase engine speed and vehicle movement. Features and Controls Throttle Lever The throttle lever is applied. Do not squeeze the throttle lever while starting the engine. Fuel is injected into the intake passage each time throttle is located on the right handlebar. See page 141 for throttle adjustment procedures. Do not squeeze the throttle lever when the engine is released. Engine speed returns to...
Owners Manual
Page 57
... up before shifting gears. 1. Release the brake lever. 6. WARNING! Features and Controls Manual Shift Shifting Gears Always allow a cold engine to disengage the clutch. 4. 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 shift into first gear. 5. Squeeze and hold the brake lever. Depress the gear shift pedal one full stroke. Always release the throttle and fully...
... up before shifting gears. 1. Release the brake lever. 6. WARNING! Features and Controls Manual Shift Shifting Gears Always allow a cold engine to disengage the clutch. 4. 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 shift into first gear. 5. Squeeze and hold the brake lever. Depress the gear shift pedal one full stroke. Always release the throttle and fully...
Owners Manual
Page 65
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 Ensure proper level Inspect for leaks Ensure smooth operation Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Verify...
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 Ensure proper level Inspect for leaks Ensure smooth operation Ensure operation Ensure proper operation Inspect, clean, replace as needed Drain deposits when visible Verify...
Owners Manual
Page 81
Stay in the clutch lever, shift into neutral and restart the engine. 10. See page 78. 77 Follow proper procedures for additional speed control if necessary, until more level ground is reached. 11. Pull in first gear, using the brakes for driving downhill. Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Operation Turning Around on a Hill 9.
Stay in the clutch lever, shift into neutral and restart the engine. 10. See page 78. 77 Follow proper procedures for additional speed control if necessary, until more level ground is reached. 11. Pull in first gear, using the brakes for driving downhill. Release the parking brake and slowly release the clutch lever, allowing the ATV to proceed slowly. Operation Turning Around on a Hill 9.
Owners Manual
Page 95
...) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Outer clutch cover -----Calendar Pre-ride in 5 (20) E X E Q z Change the oil and filters Clean screen and plug magnet Check idle speed setting Check torque Check; See Page 60 Check each day before operating the vehicle. See the Pre-Ride Checklist. 3 Break-in gallons (liters) Remarks Fuel Used ------ Perform these procedures...
...) Hours Air box sediment tubes Headlamp Tail lamp/brake lamp A-arm ball joint Rear shaft assembly Oil and filter change Oil screen/drain plug Idle speed Engine mounting bolts Valve clearance Outer clutch cover -----Calendar Pre-ride in 5 (20) E X E Q z Change the oil and filters Clean screen and plug magnet Check idle speed setting Check torque Check; See Page 60 Check each day before operating the vehicle. See the Pre-Ride Checklist. 3 Break-in gallons (liters) Remarks Fuel Used ------ Perform these procedures...
Owners Manual
Page 99
... spring length (see dealer) Check ratchet teeth for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 replace as needed Visual inspection for wear Perform these procedures more often for wear Pressure test system annually Inspect Inspect; measure; clean external surface; change coolant every 2 years Check for leaks at tank cap, lines, fuel valve, filter...
... spring length (see dealer) Check ratchet teeth for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 replace as needed Visual inspection for wear Perform these procedures more often for wear Pressure test system annually Inspect Inspect; measure; clean external surface; change coolant every 2 years Check for leaks at tank cap, lines, fuel valve, filter...
Owners Manual
Page 101
... spring; replace as needed Check entire transmission/bearings for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 97 replace as needed ; change yearly 138 Replace Replace Clean out 124 Inspect; adjust when 144 parts are replaced Adjust as needed Inspect periodically; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid...
... spring; replace as needed Check entire transmission/bearings for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 97 replace as needed ; change yearly 138 Replace Replace Clean out 124 Inspect; adjust when 144 parts are replaced Adjust as needed Inspect periodically; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Oil pressure valve Transmission QE QE Q Q Q Ignition Timing Clutch fluid...
Owners Manual
Page 120
Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 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. Position the vehicle on the wall at the same height. 3. Maintenance Lights Headlight Adjustment 1.
Measure the distance from the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 116 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. Position the vehicle on the wall at the same height. 3. Maintenance Lights Headlight Adjustment 1.
Owners Manual
Page 121
Loosen the pivot screw and adjust the beam to 27 in. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Include rider weight on the wall. lbs. (3 Nm). Pivot Screw 117 Observe the headlight aim on the wall. Maintenance Lights Headlight Adjustment 4. Tighten the screw and torque to the desired position. 6.
Loosen the pivot screw and adjust the beam to 27 in. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Include rider weight on the wall. lbs. (3 Nm). Pivot Screw 117 Observe the headlight aim on the wall. Maintenance Lights Headlight Adjustment 4. Tighten the screw and torque to the desired position. 6.
Owners Manual
Page 122
... into the lamp at outer side. 4. Oil from the back of the lamp. CAUTION! Grasp the bulb housing and turn it with bare fingers. Rotate firmly. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 2. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with...
... into the lamp at outer side. 4. Oil from the back of the lamp. CAUTION! Grasp the bulb housing and turn it with bare fingers. Rotate firmly. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 2. Maintenance Lights Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with...
Owners Manual
Page 123
Remove the wire harness connector from the headlight. 3. Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Connect the wire harness to the headlamp. Reinstall the front cover. 8. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Remove the headlamp. 5. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Maintenance Lights Headlight Assembly Replacement 1.
Remove the wire harness connector from the headlight. 3. Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Connect the wire harness to the headlamp. Reinstall the front cover. 8. Secure the headlamp with the retaining brackets. 6. Install the adjuster screw, leaving it in the slots on the frame tabs. Remove the headlamp. 5. Adjust the lamp as needed (see page 116), then tighten the adjuster screw. 119 Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Maintenance Lights Headlight Assembly Replacement 1.
Owners Manual
Page 172
Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 360 lbs./163 kg 3.1 gal./11.8 l 71.5 in./182 cm ...Needle Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 3 OBDVR 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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Specifications OUTLAW 450 MXR Max....
Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./98 kg 360 lbs./163 kg 3.1 gal./11.8 l 71.5 in./182 cm ...Needle Alternator Output Compression Ratio Starting System Carburetor Ignition System Ignition Timing Spark Plug Type Spark Plug Gap Lubrication System #45 #138 3 OBDVR 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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Specifications OUTLAW 450 MXR Max....
Owners Manual
Page 173
Rear Tire Pressure - All Front Brake Rear Brake Parking Brake Headlight Taillight Brakelight 20 x 6R10 18 x 10R9 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel Dual Beam (55w/60w) LED LED OUTLAW 450 MXR Jetting Chart ALTITUDE Meters (Feet)... Position: #2 169 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 - Specifications OUTLAW 450 MXR Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio -
Rear Tire Pressure - All Front Brake Rear Brake Parking Brake Headlight Taillight Brakelight 20 x 6R10 18 x 10R9 4 psi/27.6 KPa Hydraulic Disc, Dual Bore Hydraulic Disc Hydraulic lock, front wheel Dual Beam (55w/60w) LED LED OUTLAW 450 MXR Jetting Chart ALTITUDE Meters (Feet)... Position: #2 169 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 - Specifications OUTLAW 450 MXR Driving System Type Shift Type Primary Ratio Gear Ratio - 1st Gear Ratio - 2nd Gear Ratio - 3rd Gear Ratio - 4th Gear Ratio - 5th Gear Ratio -
Owners Manual
Page 199
... or are traveling temporarily outside the country of residence. This policy does not apply to Safety Recalls. Dealers may be requested from Polaris Industries. How to perform the warranty repair. You must be authorized to Get Service In the country where your vehicle was purchased, you have received authorization for export. You should consult an authorized dealer to...
... or are traveling temporarily outside the country of residence. This policy does not apply to Safety Recalls. Dealers may be requested from Polaris Industries. How to perform the warranty repair. You must be authorized to Get Service In the country where your vehicle was purchased, you have received authorization for export. You should consult an authorized dealer to...
Owners Manual
Page 210
... Jetting Specifications Outlaw 450 MXR ...169 Outlaw 525 S ...171 Key Switch ...39 K-Turn ...75 Lights ...40-41, 116-119 Headlight Adjustment. 116-117 Headlight Assembly ...119 Headlights...41 Indicator Lights ...40 I J Main Key Switch ...39 Maintenance Chart ...87-97 Making Turns ...69 Manual Shift ...52-55 Master Cylinder ...48-49 Modifications ...12 Oil Change, Engine...100-107 Oil Level, Engine ...99 Oil Recommendations ...98 Operator Restrictions ...15 Parking Brake ...50-51 Parking on a Hill or Incline ...79 Passenger Warning ...37 Periodic Maintenance Chart...
... Jetting Specifications Outlaw 450 MXR ...169 Outlaw 525 S ...171 Key Switch ...39 K-Turn ...75 Lights ...40-41, 116-119 Headlight Adjustment. 116-117 Headlight Assembly ...119 Headlights...41 Indicator Lights ...40 I J Main Key Switch ...39 Maintenance Chart ...87-97 Making Turns ...69 Manual Shift ...52-55 Master Cylinder ...48-49 Modifications ...12 Oil Change, Engine...100-107 Oil Level, Engine ...99 Oil Recommendations ...98 Operator Restrictions ...15 Parking Brake ...50-51 Parking on a Hill or Incline ...79 Passenger Warning ...37 Periodic Maintenance Chart...
Owners Manual
Page 212
... Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...153 Spring Preload, Front ...154 Spring Preload, Rear ...155 Starting the Engine ...66-67 Steering Inspection ...151 Storage ...162-165 Suspension Front ...153-154 Rear ...155-157 Suspension Settings ...152 Switches Engine Stop Switch ...39 Main Key Switch...39 Reverse Lock-Out Switch ...54 Start Button ...39 S Throttle Cable Freeplay...141 Throttle Lever ...44-45 Throttle Lever Freeplay...140 Tires Installation ...137 Removal ...136...
... Clean-Out...124-125 Spark Plugs...122-123 Spring Preload ...153 Spring Preload, Front ...154 Spring Preload, Rear ...155 Starting the Engine ...66-67 Steering Inspection ...151 Storage ...162-165 Suspension Front ...153-154 Rear ...155-157 Suspension Settings ...152 Switches Engine Stop Switch ...39 Main Key Switch...39 Reverse Lock-Out Switch ...54 Start Button ...39 S Throttle Cable Freeplay...141 Throttle Lever ...44-45 Throttle Lever Freeplay...140 Tires Installation ...137 Removal ...136...