Polaris Outlaw 450 MXR User manual

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.
WARNING
The engine exhaust from this
product contains chemicals known
to the State of California to cause
cancer, birth defects or other
reproductive harm.

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Visit us at www.polarisindustries.com

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2008 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 for reference use only. No liability
can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures con-
tained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2009 Outlaw 450 MXR/525 S ATV Owner's Manual
P/N 9921801

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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

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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 about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.
Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be
sure to return to your dealership for all of your service needs during, and after, the warranty
period.
We also take great pride in our Pure Polaris products, available through our online store at
www.purepolaris.com. Have your accessories and clothing delivered right to your door!

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Table of Contents
Introduction. . . . . . . . . . . . . . . . . . 6
Safety . . . . . . . . . . . . . . . . . . . . . 10
Features and Controls . . . . . . . . 38
Operation . . . . . . . . . . . . . . . . . . 58
Emission Control Systems . . . . . 85
Maintenance . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . 168
Polaris Products . . . . . . . . . . . . 172
Troubleshooting. . . . . . . . . . . . . 174
Warranty . . . . . . . . . . . . . . . . . . 186
Maintenance Log . . . . . . . . . . . 195
Index . . . . . . . . . . . . . . . . . . . . . 199

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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.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, may result in death or
serious injury.
CAUTION
A CAUTION indicates a hazardous situation
which, if not avoided, may result in minor or
moderate injury.
NOTICE
A NOTICE indicates a situation that may result in
property damage.
The Prohibition Safety Sign indicates
an action NOT to take in order to avoid
a hazard.
The Mandatory Action Sign indicates
an action that NEEDS to be taken to
avoid a hazard.

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Introduction
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
safety warnings, precautions and operating
procedures before operating a Polaris ATV.
Keep this manual with the ATV.
• Never operate an ATV without proper
instruction. Take a training course. Purchasers
of a new Polaris ATV and their eligible family
members are entitled to take the ATV
RiderCoursesm. Contact ATV Enrollment
Express at [phone] or visit
www.atvsafety.org for information on
enrollment in the ATV RiderCoursesm.
• This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16
years of age.
• Never permit a guest to operate the ATV
unless the guest has read this manual and all
product labels and has completed a certified
safety training course.
WARNING