Polaris Outlaw 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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Copyright 2005 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.
2006 Outlaw Owner’s Manual P/N 9920188

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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
VEHICLE IDENTIFICATION NUMBERS 6..............................
SAFETY 8.........................................................
FEATURES AND CONTROLS 50.....................................
OPERATION 69....................................................
EMISSION CONTROL SYSTEMS 92..................................
MAINTENANCE AND LUBRICATION 94...............................
ADJUSTMENTS 146................................................
CLEANING AND STORAGE 167......................................
TROUBLESHOOTING 174...........................................
POLARIS PRODUCTS 181...........................................
SPECIFICATIONS 182...............................................
WARRANTY 184....................................................
MAINTENANCE LOG 193............................................
INDEX 196.........................................................

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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. Your key can be duplicated only by
mating a Polaris key blank with one of your existing keys. If both keys are lost, the
ignition switch must be replaced.
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1
31XX
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VEHICLE IDENTIFICATION NUMBERS
Vehicle Model Number:
Frame VIN (1)(left side):
Engine Serial Number (2)(right side):
Key Number (3):

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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. A
B
C

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SAFETY
Safety Decals and Locations
Location B
Location C
7172560
E1997, 2000
IF OWNER’S MANUAL IS MISSING, CONTACT
A POLARIS DEALER FOR A REPLACEMENT.
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
WARNING
DNever operate this ATV on
HILLS steeper than 25 degrees
25°. To prevent flipover on
hilly terrain, when going up or
down, use throttle and brakes
gradually.
WARNING
7173837
Location A
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.
DREVERSE operation can be
dangerous, even at low speeds.
Steering becomes difficult. To prevent
flipover, avoid sudden braking or sharp
turns.
DPARKING 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
E
D
F
Location F
H
G
I
7172566
WARNING
Location E

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SAFETY
Safety Decals and Locations
ATTENTION
SOperation of this vehicle without the air filter
element will severely damage the engine.
SClean pre-filter element often, more
frequent cleaning required in dusty
conditions. Do not operate vehicle
without pre-filter.
SOperation of this vehicle without engine
breather filter(s) can cause engine
damage. Consult owner’s manual or dealer
for details.
Factory setting:
40_to 80_F. at 0-3000 feet
(5_to 27_C. at 0-900 meters).
7079902
SSpecific carburetor jetting and
adjustments are required depending on
temperature and altitude. See your Owner’s
Manual.
THIS VEHICLE IS AN ALL TERRAIN
VEHICLE AND IS NOT INTENDED FOR
USE ON PUBLIC ROADS.
7170983
CE VÉHICULE EST UN VÉHICULE TOUT
TERRAIN QUI NEST PAS DESTINE A
ETRE UTILISE SUR
LES CHEMINS
PUBLICS.
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.
L
ocation D
Location I (under seat)
L
ocation H
Location G
WARNING
7171782

E4
051039
0006.031
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SAFETY
Safe Riding Gear
Always wear clothing suited to the type of riding. ATV riding requires 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.
USA, Canada
Approved helmets in the USA and Canada bear a U.S. Department
of Transportation (DOT) label.
Europe, Asia, Oceania
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.

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SAFETY
Safe Riding Gear
2. Eye Protection
Do not depend on sunglasses for proper eye protection.
Wear shatterproof goggles or a shatterproof helmet face
shield.
3. Gloves
Off-road style gloves with knuckle pads are the best for
comfort and protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots
with heels, like moto-cross boots.
5. 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.
1
2
3
4
5

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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.

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SAFETY
Operator Safety
Operator 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.
Know Your Vehicle
As the operator of the ATV, you are responsible for your 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 ATV, including safe operating procedures.

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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 eligible family members who will be riding the
ATV to take th e 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.

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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 the ATV are thoroughly
inspected at specific intervals.