Polaris Outlaw 9921123 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 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 con-
tained within, whether whole or in part, is expressly prohibited.
Printed in U.S.A.
2007 Outlaw 525 ATV Owner's Manual
P/N 9921123

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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 Parts, Apparel and Accessories (PAA) products, available
through our online store at www.purepolaris.com. Have your accessories and clothing deliv-
ered right to your door!

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Table of Contents
Know Your Vehicle . . . . . . . . . . . . 6
Safety Decals . . . . . . . . . . . . . . . . 8
Safety . . . . . . . . . . . . . . . . . . . . . 12
Features and Controls . . . . . . . . 50
Break-In Period. . . . . . . . . . . . . . 70
Pre-Ride Inspection . . . . . . . . . . 72
Operation . . . . . . . . . . . . . . . . . . 74
Emission Control Systems . . . . . 95
Maintenance . . . . . . . . . . . . . . . . 97
Specifications . . . . . . . . . . . . . . 186
Polaris Products . . . . . . . . . . . . 188
Troubleshooting. . . . . . . . . . . . . 190
Warranty . . . . . . . . . . . . . . . . . . 202
Maintenance Log . . . . . . . . . . . 211
Index . . . . . . . . . . . . . . . . . . . . . 215

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Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal safety, the safety of oth-
ers, 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 pro-
cedures.
Vehicle Identification Numbers
Record your vehicle'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 Vehicle Identification Number (1): ______________________________________________________
Engine Serial Number (2):__________________________________________________________________
Key Number (on the key): __________________________________________________________________
2
1

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Safety Decals
Warning decals have been placed on the vehicle for your protection. Read and follow the
instructions on each decal carefully. If any of the decals shown in this manual differ from the
decals on your vehicle, always read and follow the instructions of the decals on the vehicle.
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.
Age 16
Warning
General
Warning Sport ATV
Warning
Discretionary
Warning

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Safety Decals
General Warning
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:
• without proper training or instruction
• 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:
• use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in
turns
• avoid paved surfaces - pavement may
seriously 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.
7172560

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Safety Decals
Age 16 Warning
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.
7172559
Sport ATV Warning
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.
7173837
Discretionary Warning
• Never operate this ATV on HILLS steeper than
25 degrees 25°. To prevent flipover on
hilly terrain, use throttle and brakes gradually.
• REVERSE operation can be dangerous even
at low speeds. Steering becomes difficult. To
prevent flipover, avoid sudden braking or
sharp turns.
• PARKING BRAKE may relax when used for
more than 5 minutes. When parking on
grades, leave ATV in gear.
7173837

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Safety Decals
No Passenger Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting
in SEVERE INJURY or DEATH.
7172566
Tire Pressure/Load Warning
WARNING
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control,
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 4 (27.6)
REAR 4 (27.6)
MAXIMUM WEIGHT CAPACITY
215 LBS. (97.5 KG)
INCLUDES WEIGHT OF OPERATOR, CARGO
AND ACCESSORIES
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.
7174881
Tire Pressure
Warning
No
Passenger
Warning

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Safety
Riding Gear
Always wear clothing suited to the type of riding. ATV
riding requires special protective clothing for comfort
and to reduce the chance of injury.
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 sur-
rounding the letter E, followed by the distinguishing
number of the country which has granted approval. The
approval number and serial number will also be dis-
played on the label.
Helmet
Eye
Protection Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31

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Safety
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 pair of strong over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-
pads and a jersey with shoulder pads provide the best protection.

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Safety
Operator Safety
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.
WARNING
Failure to follow the warnings 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 and understand the owner's manual and all warnings before operating a Polaris ATV.

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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 age eligible family members who
will be riding the ATV to take the ATV
RiderCoursesm.
You were 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 your vehicle are
thoroughly inspected at specific intervals.

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Safety
Operator Safety
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, on your vehicle or in this manual, alerts you to the potential for injury.
WARNING
The safety alert warning indicates a potential hazard that may result in serious injury or death.
CAUTION
The safety alert caution indicates a potential hazard that may result in minor injury or damage to the
vehicle.
CAUTION
A caution indicates a situation that may result in damage to the vehicle.
NOTE:
A note will alert you to important information or instructions.

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Safety
Operator Safety
• Read this manual and all labels carefully.
Follow all operating procedures.
• Never operate an ATV without proper
instruction. Take a training course. Pur-
chasers of a new Polaris ATV and age eli-
gible 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.
• Never allow anyone under 16 years of
age to operate this ATV.
• 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.
• Always avoid operating an ATV on any
paved surfaces, including sidewalks,
driveways, parking lots and streets.
WARNING
Serious injury or death can result if you do not follow these instructions and procedures, which are
outlined in further detail within your owner's manual.