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2010
Outlaw 525 IRS
Owner's Manual
for Maintenance
and Safety
This Category "S" (Sport) ATV is a high-performance ATV for off-road use only. It is
for sport-type recreational and competitive use by operators with advanced skills and
substantial experience. Operation is prohibited for anyone under 16 years of age.
Read this manual carefully.
It contains important safety information.
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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.
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The text is printed on 100% recycled with 40% post-consumer waste (PCW).
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WARNING NEVER operate: Improper ATV use can result in without proper training or instruction SEVERE INJURY or DEATH. at speeds too fast for your skills or the conditions on public roads - a collision can occur with another vehicle with a passenger - passengers affect balance and steering and increase risk of losing control ALWAYS: ALWAYS USE NEVER USE NEVER CARRY NEVER USE PASSENGERS use proper riding techniques to avoid vehicle AN APPROVED ON PUBLIC WITH DRUGS HELMET AND ROADS OR ALCOHOL ove
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Visit us at www.polarisindustries.com 1
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POLARIS, THE WAY OUT and OUTLAW are registered trademarks of Polaris Industries Inc. Copyright 2009 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. Depictions and/or procedures in this publication are intended
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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 3
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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. For safe and enjoyable operation of your vehicle, be sure to follow the instructions and rec- ommendations in this owner's manual. Your manual contains instructions for minor mainte- nance, but information ab
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Table of Contents Introduction. . . . . . . . . . . . . . . . . . 6 Specifications . . . . . . . . . . . . . . 168 Safety . . . . . . . . . . . . . . . . . . . . . 10 Polaris Products . . . . . . . . . . . . 170 Features and Controls . . . . . . . . 38 Troubleshooting. . . . . . . . . . . . . 172 Operation . . . . . . . . . . . . . . . . . . 58 Declaration of Conformity . . . . . 184 Emission Control Systems . . . . . 83 Warranty . . . . . . . . . . . . . . . . . . 187 Maintenance . . . . . . .
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Introduction Safety Words and Symbols 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 indicates a potential personal injury hazard. The Prohibition Safety Sign indicates WARNING an action NOT to take in order to avoid a hazard. A WARNING indicates a hazardous situation The Mandatory Action Sign indica
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Introduction WARNING Failure to follow the warnings and safety precautions contained 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. • Read this owner’s manual. Understand all • Thi
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Introduction Service Requirements 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 recom- mended procedures at the service intervals specified in your owner’s manual will void war- ranty coverage and decrease the performance and reliability of your vehicle. Vehicle Identification Number
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Introduction Vehicle Identification Numbers 1 2 Vehicle Model Number: ____________________________________________________________________ Frame Vehicle Identification Number (1): ______________________________________________________ Engine Serial Number (2):__________________________________________________________________ Key Number (on the key): __________________________________________________________________ 9
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Safety Safety Training ATV safety training is a top priority for If you purchased a used Polaris ATV in the Polaris. Polaris strongly encourages you and United States, you can enroll in the ATV sm any family members who will be riding the RiderCourse for a fee. Call ATV ATV to take a training course. Enrollment Express at (800) 887-2887 or visit www.atvsafety.org. If you purchased a new Polaris ATV in the United States, your dealer provided If you purchased a Polaris ATV outside the instru
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Safety Safety Training A Polaris ATV is an off-road vehicle. Follow the recommended maintenance Familiarize yourself with all laws and program outlined in your owner's manual. regulations concerning the operation of this This program is designed to ensure that all vehicle in your area. critical components on your vehicle are thoroughly inspected at specific intervals. FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Con- sumer Product Safety Commission at 1-800-638-2772,
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Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substan- tial safety hazard and increase the risk of bodily injury. The warranty on your Polaris ATV is ter
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Safety Safe Riding Gear Long Always wear clothing suited to the type of riding. ATV Helmet Sleeves riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. When- Eye ever riding a Polaris vehicle, always wear a helmet that Gloves meets or exceeds established safety standards. Protection Approved helmets in the USA and Canada bear a U.S. Long Department of Transportation (DOT) label. Pants Approved
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Safety Safe 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. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. Boots The best footwear is a
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Safety Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Operator Restrictions/Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. This category S (Sport) ATV i
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Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain. Beginning and inexperienced operators should complete the ATV sm 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 Manu
