Polaris Outlaw 450, 525 (MXR, S, IRS) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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POLARIS OUTLAW 450, 525 (MXR, S, IRS) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for ATV Polaris Outlaw 450, 525 (MXR, S, IRS).

 
CONTENTS:

SERVICE MANUAL

General Information
Vehicle Identification
- Model Identification
- Engine Designation Numbers
- VIN Identification
- Vehicle Identification Number (VIN) Location
- Engine Serial Number Location
Vehicle Information
- Paint Codes
- Replacement Keys
- Publication Numbers
- Standard Torque Specifications
Specifications
- MODEL: 2009 OUTLAW 450 “MXR”
- MODEL: 2009 OUTLAW 525 “S”
- MODEL: 2009 OUTLAW 525 “IRS”
- 2009 OUTLAW 450 “MXR”
- 2009 OUTLAW 525 “S”
- 2009 OUTLAW 525 “IRS”
Special Tools
- “Chassis” Special Tools
- “KTM Engine” Special Tool Cross-Reference
- KTM Engine Special Tools
Misc. Numbers / Charts
- SAE Tap / Drill Sizes
- Metric Tap / Drill Sizes
- Decimal Equivalents
- Coversion Table
- Glossary of Terms
Maintenance
Periodic Maintenance Chart
- Periodic Maintenance Overview
- Break-In Period
- Maintenance Chart Key
- Pre-Ride Maintenance Interval
- Recommended Pre-Ride Fluid Level Checks
- 10 - 60 Hour Maintenance Interval
- 45 - 90 Hour Grease Lubrication Maintenance Interval
- 90 - 300 Hour Maintenance Interval
- Maintenance References
Lubricants And Service Products
- Polaris Lubricants, Maintenance and Service Products
General Vehicle Inspection And Maintenance
- Pre-Ride / Daily Inspection
- Frame, Nuts, Bolts, and Fasteners
Fuel System And Air Intake
- Fuel System
- Fuel Lines
- Vent Lines
- Fuel Valve
- Carburetor General Maintenance
- Carburetor Draining
- Idle Speed Adjustment
- Throttle Inspection
- Throttle Cable / Electronic Throttle Control (ETC) Adjustment
- Choke Operation
- Air Filter Service (“MXR” / “S”)
- Air Filter Service (“IRS”)
- Air Box Drain Tube
Engine And Transmission
- Engine Oil Level
- Engine Oil and Filter Service
- Cylinder Leakdown Test
- Valve Clearance Adjustment
- Exhaust Pipe / Spark Arrestor
- Engine Mount Locations
Liquid Cooling System
- Cooling System Overview
- Coolant Strength / Type
- Cooling System Hoses
- Recovery Bottle / Coolant Level Inspection
- Radiator / Coolant Level Inspection
- Cooling System Bleeding
- Radiator Screen Removal
Final Drive
- Hydraulic Clutch Lever Adjustment
- Hydraulic Clutch Oil level Inspection
- Hydraulic Clutch System Bleeding
- Reverse Lock-Out Lever Inspection and Cable Adjustment
- Sprocket Inspection
- Drive Chain Inspection / Replacement
- Drive Chain Tension
- Drive Chain Adjustment (“MXR” / “S”)
- Drive Chain Adjustment (“IRS”)
- Rear Driveshaft Boot Inspection (“IRS”)
- Driveshaft Boot Pressure Equalizing (“IRS”)
Electrical And Ignition System
- Battery Maintenance
- Battery Inspection / Removal
- Battery Terminals / Bolts
- Off Season Storage
- Charging Procedure (“MXR” / “S”)
- Charging Procedure (“IRS”)
- Spark Plug Removal / Inspection
Steering
- General Steering Information
- Controls / Handlebar
- Steering Inspection / Tie Rod Ends and Hubs
- Toe Alignment Inspection
- Toe Adjustment
Suspension (450 “Mxr” / 525 “S”)
- Front Suspension Set-Up
- Front Spring Preload Adjustment
- Front Shock Compression Adjustment (“MXR”)
- Rear Suspension Set-Up
- Rear Spring Preload Adjustment
- Rear Shock Compression Adjustment
- Rear Shock Rebound Adjustment
Suspension (525 “Irs”)
- Front Suspension Set-Up
- Front Spring Preload Adjustment
- Rear Suspension Set-Up
- Rear Spring Preload Adjustment
- Rear Shock Compression Adjustment
Brake System
- Brake System Inspection
- Brake Pad Inspection
- Brake Lever Position Adjustment
- Brake Pedal Testing / Brake Light Operation
Wheels And Tires
- Wheels
- Wheel, Hub, and Spindle Torque Table
- Wheel Removal: Front or Rear
- Tire Pressure
- Tire Inspection
Maintenance Log
Engine
Engine Service
- KTM 450/525 Engine
General Engine Information
- Special Tools
- Accessible Components
- Engine Removal
- Engine Installation Notes
- Engine Break-In Period
- ES45KL / ES51KL Engine Lubrication
Engine Cooling System
- Coolant Temperature Sensor (Dual Temp Thermal Sensor)
- Cooling System Flow Chart
- Cooling System Pressure Test
- Cooling System Specifications
Fuel System
Carburetor Service
- Keihin FCR-MX 39 mm Carburetor
General Information
- Jetting Guidelines
- Carburetor Jetting
- Keihin Optional Jet Part Numbers
Keihin Fcr-Mx 3900 Carburetor
- Exploded View
Fuel Tank
- Exploded View
- Fuel Tank Removal
Fuel Pump
- Location / Operation
- Service / Replacement
Body / Steering / Suspension
General Information
- Torque Specifications
- Special Tools
Body Assembly
- Exploded View
Body Component Removal
- Seat
- Front Cover
- Front Cab
- Side Panels
- Rear Cab
- Heel Pocket
Steering Assembly Exploded View
Steering Knuckle
- Removal
- Installation
Ball Joint Service
- Removal
- Installation
Front Wheel Hub
- Exploded View
- Wheel Hub Removal
- Wheel Hub Disassembly
- Wheel Hub Assembly
- Wheel Hub Installation
Front Suspension Exploded View
Front A-Arm Replacement
- A-arm Removal and Inspection
- A-arm Installation
Rear Suspension Exploded View (“Irs”)
Rear A-Arm Replacement (“Irs”)
- A-arm Removal
- A-arm Inspection
- A-arm Installation
Rear Housing (“Irs”)
- Exploded View
- Housing Removal
- Housing Disassembly / Service
- Assembly
- Installation
Rear Bearing Carrier (“Irs”)
- Carrier Removal
- Carrier Disassembly / Inspection
- Carrier Assembly
- Carrier Installation
Rear Drive Cv Joint (“Irs”)
- CV Joint Removal
- CV Joint Service
- CV Joint Installation
Rear Suspension Service (“Mxr” / “S”)
- Swing Arm Removal / Installation
Rear Axle Service (“Mxr” / “S”)
- Removal / Disassembly
- Installation / Assembly
- Axle Run-Out Inspection
Rear Axle Housing / Axle (“Mxr” / “S”)
- Exploded View
Decal Replacement
Front Shock Exploded Views
- FOX™ PODIUM X ‘Piggyback’ Front Shock (450 “MXR”)
- FOX™ PODIUM Front Shock (525 “S” / 525 “IRS”)
Rear Shock Exploded Views
- FOX™ PODIUM X ‘Piggyback’ Rear Shock (450 “MXR” / 525 “S”)
- FOX™ PODIUM-C Rear Shock (525 “IRS”)
Fox™ Podium Shock Service
- General Service Information
- FOX™ Front Shock Disassembly
- FOX™ Front Shock Assembly
- Shock Eyelet Replacement
Fox™ Podium X Shock Service
- General Service Information
- Front Shock Service Information (450 “MXR”)
- Rear Shock Service Information (450 “MXR” / 525 “S”)
- FOX™ PODIUM X Shock Rebuild Information
- FOX™ Podium X Shock Disassembly
- FOX™ Podium X Shock Rebuild
- FOX™ Podium X Shock Assembly
Fox™ Podium-C Shock Service
- General Service Information
- FOX™ PODIUM-C Rebuild Information
- FOX™ PODIUM-C Shock Disassembly
- FOX™ PODIUM-C Shock Assembly
Brakes
Brake Specifications
- General Specifications
- Torque Specifications
- Special Tools
Brake Caliper Exploded Views
- Front Brake Caliper Assembly
- Rear Brake Caliper Assembly
Brake System Overview
- Hydraulic System Operation
- Front Brake System - Exploded View
- Rear Brake System (“MXR” / “S”) - Exploded View
- Rear Brake System (“IRS”) - Exploded View
- Service Notes
- Brake Noise Troubleshooting
- Brake Fluid Replacement and Bleeding Procedure
Front Master Cylinder
- Brake Lever Position Adjustment
- Removal
- Installation
Front Caliper Service
- Caliper Removal and Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
Front Brake Pads
- Pad Removal
- Pad Assembly
- Brake Burnishing Procedure
Front Brake Disc
- Disc Inspection
- Disc Removal / Replacement
Rear Caliper Service
- Caliper Removal (“MXR” / “S”)
- Caliper Removal (“IRS”)
- Caliper Disassembly
- Caliper Inspection
- Caliper Reassembly
- Caliper Installation (“MXR” / “S”)
- Caliper Installation (“IRS”)
Rear Brake Pads
- Pad Removal
- Pad Installation
- Brake Burnishing Procedure
Rear Brake Disc
- Disc Inspection
- Disc Removal / Replacement (“MXR” / “S”)
- Disc Removal / Replacement (“IRS”)
- Disc Installation
Troubleshooting
- Brakes Squeal
- Poor Brake Performance
- Lever Vibration
- Brakes Lock
Electrical
General Information
- Special Tools
- Electrical Service Notes
Component Location (Chassis)
- 450 “MXR” / 525 “S”
- 525 “IRS”
Lighting And Controls
- Transmission Switch Test
- Headlight Bulb Replacement
- Headlight Housing Replacement
- Headlight Adjustment
- Headlamp Switch Test
- Taillight / Brakelight Lamp Replacement
- Brake Light Switch Tests
- Clutch Switch Test
- Tether Switch Test (Accessory Option)
- Indicator Lamp Replacement
- Electronic Throttle Control (ETC) Switch
- ETC Operation Test
Ignition System
- Ignition System Troubleshooting
- DC / CDI Ignition
- Circuit Breakers
- Cranking Output Tests
- Ignition System Breakout Diagram
- Ignition System Testing
- Components of DC / CDI Ignition
Cooling System
- Fan Control Circuit Operation
- Fan Switch Bypass Tests
- Fan Switch “Hot Light” Operation
Charging System
- Current Draw - Key Off
- Charging System “Break Even” Test
- Alternator Tests (Charging System)
- Charging System Testing Flow Chart
Battery Tests
- Battery Testing
- OCV - Open Circuit Voltage Test
- Load Test
- Battery Terminals / Bolts
- Battery Maintenance / Inspection / Removal
- Battery Charging Procedure
Starting System
- Starting System Circuit
- Starter System Troubleshooting
- Clutch Switch Test
- Neutral Start Diode Test
- Starter Voltage Drop Testing
- Starter Motor Removal
- Starter Motor Exploded View
- Starter Motor Disassembly
- Brush Inspection / Replacement
- Armature Testing
- Starter Reassembly
- Starter Motor Installation
- Starter One-Way Clutch Inspection
- Starter System Testing Flow Chart


OWNERS MANUAL 450
OWNERS MANUAL 525