Polaris Outlaw 9920783 User manual

WARNING
The engine exhaust from this
product contains chemicals known
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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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2006 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 contained
within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2007 Outlaw Owner’s Manual P/N 9920783

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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.
SSnowmobiles
SAll-terrain vehicles (ATVs)
SRANGER utility vehicles
SVictory motorcycles

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WELCOME
We believe Polaris sets a standard of excellence for all utility and recreational vehicles
manufactured 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
recommendations in this owner’s manual. Your manual contains instructions for minor
maintenance, 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 Parts, Apparel and Accessories (PAA) 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
KNOW YOUR VEHICLE 6...........................................
SAFETY 8.........................................................
FEATURES AND CONTROLS 48.....................................
OPERATION 67....................................................
EMISSION CONTROL SYSTEMS 90..................................
MAINTENANCE AND LUBRICATION 92...............................
ADJUSTMENTS 146................................................
CLEANING AND STORAGE 167......................................
TROUBLESHOOTING 176...........................................
POLARIS PRODUCTS 183...........................................
SPECIFICATIONS 184...............................................
WARRANTY 186....................................................
MAINTENANCE LOG 195............................................
INDEX 198.........................................................

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KNOW YOUR VEHICLE
As the operator of the vehicle, you are responsible for your personal safety, the safety of
others, and the protection of our environment. Read and understand your owner’s manual,
which includes valuable information about all aspects of your vehicle, including safe
operating procedures.
Vehicle Identification Numbers
Record your ATV’s identification numbers and key number in the spaces provided.
Remove the spare key and store it in a safe place. An ignition key can be duplicated only
by ordering a Polaris key blank (using your key number) and mating it with one of your
existing keys. The ignition switch must be replaced if all keys are lost.

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KNOW YOUR VEHICLE
Vehicle Identification Numbers
Vehicle Model Number:
Frame VIN (1)(left side):
Engine Serial Number (2)(right side):
Key Number (3):
2
1
31XX
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SAFETY
Safety Decals and Locations
Warning decals have been placed on the ATV for your protection. Read and follow the
instructions of the decals on the ATV carefully. If any of the decals depicted in this manual
differ from the decals on your ATV, always read and follow the instructions of the decals on
the ATV.
If any decal becomes
illegible or comes off,
contact your Polaris
dealer to purchase a
replacement.
Replacement safety
decals are provided
by Polaris at no
charge. The part
number is printed
on the decal. 4
1
2
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SAFETY
Safety Decals and Locations
General Warning (1)
WARNING
Improper ATV use can result in SEVERE
INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND
PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
Swithout proper training or instruction
Sat speeds too fast for your skills or the condi-
tions
Son public roads -- a collision can occur with
another vehicle
Swith a passenger -- passengers affect balance
and steering and increase risk of losing control
ALWAYS:
Suse proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
Savoid paved surfaces -- pavement may seri-
ously affect handling and control
LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND
WARNINGS.
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.

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SAFETY
Safety Decals and Locations
Age16Warning(2)
WARNING
Operating this ATV if you are under the age of 16
increases your chance of severe injury or death.
NEVER operate this ATV if you are under age
16.
Sport ATV Warning (3)
WARNING
This ATV may exceed the performance of other
ATVs you may have ridden in the past. This
category S (Sport) ATV is a high performance
vehicle for off-road use only, in sport type
recreation and competitive use by operators with
advanced skills and substantial experience.
Discretionary Warning (4)
WARNING
SNever operate this vehicle on HILLS steeper
than 25 degrees 25°. To prevent flipover
on hilly terrain, when going up or down, use
throttle and brakes gradually.
SREVERSE operation can be dangerous, even
at low speeds. Steering becomes difficult. To
prevent flipover, avoid sudden braking or sharp
turns.
SPARKING BRAKE may relax when used for
more than 5 minutes. When parking on grades,
leave ATV in gear.

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SAFETY
Safety Decals and Locations
No Passenger Warning (5)
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control,
resulting in SEVERE INJURY or DEATH.
Tire Pressure/Load Warning (6)
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 5
(34,5) REAR 5 (34,5)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle
Weight) INCLUDING MACHINE, DRIVER AND
CARGO IS 660 LBS. (299 kg).
Reduce speed and allow greater distance for
braking when carrying cargo. Overloading or
carrying tall, off-center, or unsecured loads will
increase your risk of losing control. For stability
on rough or hilly terrain, reduce speed and
cargo.
Read Owner’s Manual for more detailed loading
information.
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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear
protective clothing for comfort and to reduce the chance of injury.
1. Helmet
Wearing a helmet can prevent a severe head injury. Whenever
riding a Polaris vehicle, always wear a helmet that meets or
exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark
consists of a circle surrounding the letter E,
followed by the distinguishing number of the
country which has granted approval. The
approval number and serial number will also be
displayed on the label.
1
2
3
5
4
E4
051039
0006.031

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SAFETY
Safe Riding Gear
2. 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.
3. Gloves
Off-road style gloves with knuckle pads are
the best for comfort and protection.
4. Clothing
Always wear long sleeves and long pants to
protect arms and legs. Riding pants with
kneepads and a jersey with shoulder pads
provide the best protection.
5. Boots
The best footwear is a pair of sturdy
over-the-calf boots with low heels.

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SAFETY
Operator Safety
WARNING
Failure to follow the warnings contained in this manual can result in serious 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 and understand your owner’s manual and all warnings before operating a
Polaris ATV.
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 is a high performance vehicle intended for off
road use only, for sport-type recreation and for competitive use by operators with advanced
skills and substantial experience.

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SAFETY
Operator Safety
Safety Training
ATV safety training is a top priority for
Polaris. When you purchased your new
ATV, your dealer instructed you on the
authorized ATV RiderCoursesm available to
you and your eligible family members.
This training is included in the purchase
price of your ATV. Polaris strongly
encourages you and your eligible family
members who will be riding the ATV to
take the ATV RiderCoursesm.Youwere
also provided with printed materials that
explain safe operating procedures. You
should review this information on a regular
basis.
If you purchased a used Polaris ATV, you
can take the ATV RiderCoursesm by calling
ATV Enrollment Express at [phone]
or by visiting www.atvsafety.org.
Purchasers of a used Polaris ATV will be
charged for this training.
A Polaris ATV is an off-road vehicle.
Familiarize yourself with all laws and
regulations concerning the operation of this
vehicle in your area.
Follow the recommended maintenance
program outlined in your owner’s manual.
This program is designed to ensure that all
critical components on the ATV are
thoroughly inspected at specific intervals.

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SAFETY
Operator Safety
The following two pages identify signal words and symbols that appear in this manual.
Your safety is involved when these words and symbols are used. Become familiar with
their meanings before reading the manual.
The safety alert symbol, on your vehicle or in this manual, alerts you to the potential
for personal injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious injury
or death.

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SAFETY
Operator Safety
CAUTION
The safety alert caution indicates a potential hazard that may result in minor personal
injury or damage to the vehicle.
CAUTION
Acaution indicates a situation that may result in damage to the vehicle.
NOTE:
Anote will alert you to important information or instructions.