Polaris Outlaw 9922079 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 525 IRS ATV Owner's Manual
P/N 9922079

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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 . . . . . 86
Maintenance . . . . . . . . . . . . . . . . 85
Specifications . . . . . . . . . . . . . . 168
Polaris Products . . . . . . . . . . . . 170
Troubleshooting. . . . . . . . . . . . . 172
Warranty . . . . . . . . . . . . . . . . . . 184
Maintenance Log . . . . . . . . . . . 193
Index . . . . . . . . . . . . . . . . . . . . . 197

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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

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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 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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Introduction
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
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 materi-
als 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.

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Safety
Safety 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.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety
Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.

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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 terminated if any equipment has been added to the
vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires,
sprayers, or large racks, may change the handling characteristics of the vehicle. Use only
Polaris-approved accessories, and familiarize yourself with their function and effect on the
vehicle.

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Safety
Safe 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. When-
ever 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 num-
ber of the country which has granted approval. The
approval number and serial number will also be displayed
on the label.
Helmet
Eye
Protection Gloves
Boots
Long
Pants
Long
Sleeves
E
4
051039
0006.31

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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 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
Safety Warnings
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 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.
Even though a child may be within the recommended age group for
operating some ATVs, he/she may not have the skills, abilities, or
judgment needed to operate an ATV safely and could be susceptible to
accident or injury.
WARNING

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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
RiderCoursesm 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 Manual.
For more information about the ATV RiderCoursesm contact ATV
Enrollment Express at [phone] or visit www.atvsafety.org.
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.

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Safety
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive
under certain conditions.
• Always exercise extreme caution whenever
handling gasoline.
• Always refuel with the engine stopped, and
outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks
in or near the area where refueling is per-
formed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank
neck.
• If gasoline spills on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can
cause loss of consciousness or death in a short
time. Never start the engine or let it run in an
enclosed area.
The engine exhaust from this product contains
chemicals known to cause cancer, birth defects
or other reproductive harm. Operate this vehicle
only outdoors or in well-ventilated areas.