Owners Manual
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Operation is a high-performance ATV for off-road use by operators with advanced skills and substantial experience. Read this manual carefully. 2010 Outlaw 525 IRS Owner's Manual for Maintenance and Safety This Category "S" (Sport) ATV is prohibited for anyone under 16 years of age. It is for sport-type recreational and competitive use only. It contains important safety information.
Operation is a high-performance ATV for off-road use by operators with advanced skills and substantial experience. Read this manual carefully. 2010 Outlaw 525 IRS Owner's Manual for Maintenance and Safety This Category "S" (Sport) ATV is prohibited for anyone under 16 years of age. It is for sport-type recreational and competitive use only. It contains important safety information.
Owners Manual
Page 4
... 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 ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS: use can occur with another vehicle with a passenger - For your skills or the conditions on hills and...
... 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 ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ALWAYS: use can occur with another vehicle with a passenger - For your skills or the conditions on hills and...
Owners Manual
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... vehicle and the information presented in part, is based on the latest product information at the time of Polaris Industries Inc. Copyright 2009 Polaris Sales ...Inc. Any reprinting or reuse of the depictions and/or procedures contained within this publication are registered trademarks of publication. Printed in this publication is expressly prohibited. POLARIS, THE WAY OUT and OUTLAW are intended for omissions or inaccuracies. Depictions and/or procedures in U.S.A. 2010 OUTLAW 525 IRS ATV Owner's Manual...
... vehicle and the information presented in part, is based on the latest product information at the time of Polaris Industries Inc. Copyright 2009 Polaris Sales ...Inc. Any reprinting or reuse of the depictions and/or procedures contained within this publication are registered trademarks of publication. Printed in this publication is expressly prohibited. POLARIS, THE WAY OUT and OUTLAW are intended for omissions or inaccuracies. Depictions and/or procedures in U.S.A. 2010 OUTLAW 525 IRS ATV Owner's Manual...
Owners Manual
Page 65
... lamp is replaced Check operation, adjust brake light switch Wear helmet, goggles, protective clothing Check freeplay. 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...
... lamp is replaced Check operation, adjust brake light switch Wear helmet, goggles, protective clothing Check freeplay. 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...
Owners Manual
Page 81
... the clutch lever, shift into neutral and restart the engine. 10. With the front brakes still applied, release the clutch lever and lock the parking brake. Release the parking brake and slowly release the clutch lever, allowing the ATV to your right until more level ground is reached. 11. See page 75. 77 Remount from the uphill side, keeping body 8 ft. (2.4 m) weight uphill. 9. Follow proper procedures for additional speed control...
... the clutch lever, shift into neutral and restart the engine. 10. With the front brakes still applied, release the clutch lever and lock the parking brake. Release the parking brake and slowly release the clutch lever, allowing the ATV to your right until more level ground is reached. 11. See page 75. 77 Remount from the uphill side, keeping body 8 ft. (2.4 m) weight uphill. 9. Follow proper procedures for additional speed control...
Owners Manual
Page 93
... 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. 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 clearance...
... 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. 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 clearance...
Owners Manual
Page 97
... --------- change coolant every 2 years Check for wear Pressure test system annually Inspect Inspect; clean external surface; X QE E Check spring length (see dealer) Check ratchet teeth for leaks at tank cap, lines, fuel valve, filter, carburetor; replace lines every two years Inspect; measure; replace as needed Visual inspection for wear Perform these procedures more often for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris...
... --------- change coolant every 2 years Check for wear Pressure test system annually Inspect Inspect; clean external surface; X QE E Check spring length (see dealer) Check ratchet teeth for leaks at tank cap, lines, fuel valve, filter, carburetor; replace lines every two years Inspect; measure; replace as needed Visual inspection for wear Perform these procedures more often for vehicles subjected to severe use Emission-Related Service Have an authorized Polaris...
Owners Manual
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... Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 change yearly 140 Replace Replace Clean out 124 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 aim X E Q z 90 90 -90 180 180 300 300 Calendar --in gallons (liters) Remarks Fuel Used...
... Emission-Related Service Have an authorized Polaris dealer perform these services Use Polaris Premium All Season Grease 95 change yearly 140 Replace Replace Clean out 124 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 aim X E Q z 90 90 -90 180 180 300 300 Calendar --in gallons (liters) Remarks Fuel Used...
Owners Manual
Page 119
Position the vehicle on the wall at the same height. 3. Measure the distance from a flat wall. 2. 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 the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 115 Maintenance Lights Headlight Adjustment 1.
Position the vehicle on the wall at the same height. 3. Measure the distance from a flat wall. 2. 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 the floor to high beam. 25 ft. (7.6 m) Lamp Center Height 2" (5 cm) General Representation 115 Maintenance Lights Headlight Adjustment 1.
Owners Manual
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Include rider weight on the wall. Loosen the pivot screw and adjust the beam to 27 in. lbs. (3 Nm). Tighten the screw and torque to the desired position. 6. Maintenance Lights 4. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Pivot Screw 116 Observe the headlight aim on the wall.
Include rider weight on the wall. Loosen the pivot screw and adjust the beam to 27 in. lbs. (3 Nm). Tighten the screw and torque to the desired position. 6. Maintenance Lights 4. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mark placed on the seat when measuring. 5. Pivot Screw 116 Observe the headlight aim on the wall.
Owners Manual
Page 121
... to cool before servicing. 3. Allow lamps to the socket and install the new bulb. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 117 If fingers do touch a lamp, clean it counterclockwise to skin. Hot components can cause burns to remove the bulb. Maintenance Lights Headlight Lamp Replacement When servicing...
... to cool before servicing. 3. Allow lamps to the socket and install the new bulb. Remove the wire harness connector from your skin leaves a residue, causing a hot spot that will shorten the life of the headlight. 117 If fingers do touch a lamp, clean it counterclockwise to skin. Hot components can cause burns to remove the bulb. Maintenance Lights Headlight Lamp Replacement When servicing...
Owners Manual
Page 122
Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Install the adjuster screw, leaving it in the slots on the frame tabs. Adjust the lamp as needed (see page 115), then tighten the adjuster screw. 118 Remove the wire harness connector from the headlights. 3. Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Secure the headlamp with the retaining brackets. 6. Remove the headlamp. 5. Reinstall the front cover. 8. Maintenance Lights Headlight Assembly Replacement 1. Connect the wire harness to the headlamp.
Remove the front cover. 2. Remove the two retaining brackets and the adjuster screw. 4. Install the adjuster screw, leaving it in the slots on the frame tabs. Adjust the lamp as needed (see page 115), then tighten the adjuster screw. 118 Remove the wire harness connector from the headlights. 3. Install the new headlamp, placing it loose so the headlight can be adjusted. 7. Secure the headlamp with the retaining brackets. 6. Remove the headlamp. 5. Reinstall the front cover. 8. Maintenance Lights Headlight Assembly Replacement 1. Connect the wire harness to the headlamp.
Owners Manual
Page 123
... to decrease tension on the spring if the brake light comes on when there is no pressure on and off with a pliers or similar tool and hold it lightly, but securely. If the light does not operate properly, grasp the switch body with each use of the brake pedal. 3. Turn the ignition key on the spring. Switch Body Adjustment Nut Spring TIP: Rotate the adjusting nut...
... to decrease tension on the spring if the brake light comes on when there is no pressure on and off with a pliers or similar tool and hold it lightly, but securely. If the light does not operate properly, grasp the switch body with each use of the brake pedal. 3. Turn the ignition key on the spring. Switch Body Adjustment Nut Spring TIP: Rotate the adjusting nut...
Owners Manual
Page 157
...), increase spring preload and repeat all steps. Subtract the step 8 measurement from the step 4 measurement. Turn the handlebars fully to the left and right. 8. 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...
...), increase spring preload and repeat all steps. Subtract the step 8 measurement from the step 4 measurement. Turn the handlebars fully to the left and right. 8. 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...
Owners Manual
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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 higher than 4.25 inches (10.8 cm), decrease the rear spring preload on the handlebars. 6. Subtract the step 8 measurement from the step...
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 higher than 4.25 inches (10.8 cm), decrease the rear spring preload on the handlebars. 6. Subtract the step 8 measurement from the step...
Owners Manual
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Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./97.5 kg 389 lbs./176 ...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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Dry Sump/Internal Reservoir 168 Specifications OUTLAW 525 IRS...
Turning Radius Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke 215 lbs./97.5 kg 389 lbs./176 ...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. Weight Capacity Dry Weight Fuel Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Min. Dry Sump/Internal Reservoir 168 Specifications OUTLAW 525 IRS...
Owners Manual
Page 173
Rear Tire Pressure - 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 Dual Beam (55w/60w) LED LED Jetting Chart ALTITUDE Meters (...: #4 Main Jet: 138 Needle Clip Position: #3 169 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...
Rear Tire Pressure - 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 Dual Beam (55w/60w) LED LED Jetting Chart ALTITUDE Meters (...: #4 Main Jet: 138 Needle Clip Position: #3 169 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...
Owners Manual
Page 197
... policy does not apply to vehicles registered to Safety Recalls. Outside the country where your vehicle was purchased: If you are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may not give authorization for export from Polaris Industries. This policy does not apply to an authorized Polaris dealer. EXPORTED VEHICLES Warranty 193 This policy does not...
... policy does not apply to vehicles registered to Safety Recalls. Outside the country where your vehicle was purchased: If you are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may not give authorization for export from Polaris Industries. This policy does not apply to an authorized Polaris dealer. EXPORTED VEHICLES Warranty 193 This policy does not...
Owners Manual
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... Tread Lightly ...64 Turning Around on a Hill ...76-77 T 206 Index Side 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...
... Tread Lightly ...64 Turning Around on a Hill ...76-77 T 206 Index Side 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...