Instruction/ maintenance manual of the product 525 S Polaris
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A card containing importan t A TV safety information sh ould be attached to the owner's manual on the next page. If you cann ot locate this card, or if it has been removed, please ca ll 1-800-342-3764 for assista nce.
1 Visit us at www .polarisindustries.com.
2 POLARIS and POLARIS TH E W A Y OUT are register ed t rademarks of Polari s Industries Inc. Copyright 2007 Polaris Sales Inc. All in formation contained within this publication is based on the latest p roduct information at the time of publicat ion.
3 We l c o m e Thank you for purchasin g a Polaris vehicle, and welcome to our world-wide family of Polaris owners. W e proudly produce an exciti ng line of utility and recreational products.
4 We l c o m e W e believe Polaris sets a standard of excellen ce for all utility and re creational vehicles man- ufactured in the worl d today . Many years of experience have gone into the engineering, design, and developmen t of your Polaris vehicl e, making it the finest machine we 've ever produced.
5 T able of Contents Know Y our V ehicle . . . . . . . . . . . . 6 Safety Decals . . . . . . . . . . . . . . . . 8 Safety . . . . . . . . . . . . . . . . . . . . . 12 F eatures and Controls . . . . . . . . 50 Break-In P eriod . . . . . . . . . . . . .
6 Know Y our V ehicle As the operator of the vehicle, you are responsi ble for your personal safety , the safety of oth- ers, and the protection of our en vironment. Re ad an d understand your owner's manual , which includes valuable information abou t all aspects of your vehicle, includi ng safe operating pro- cedures.
7 Know Y our V ehicle V ehicle Identification Numbers V ehicle Model Number: _________________________________________________________________ ___ F rame V ehicle Identifica tion Number (1): _________.
8 Safety Decals W arning decals have been placed o n the vehicle for your prot ection. Read and follow the instructions on each decal carefully . If any of th e decals shown in this manual differ from the decals on your vehicle, always read and follow the instructions of the decals on the vehicle.
9 Safety Decals General Warning WARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gear . Never use on public roads.
10 Safety Decals Age 16 W arning WARNING Operating this A TV if you are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7172559 Sport A TV W arning WARNING This A TV may exceed the performance of other A TVs you may have ridden in the past.
11 Safety Decals No P assenger W arning WARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. 7172566 Tire Pressure/Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERL OADING can cause loss of control, resulting in SEVERE INJURY OR DEA TH.
12 Safety Riding Gear Always wear clothing suited to the type o f riding. A TV riding requires special prot ective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prev ent a severe head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.
13 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses fo r eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet fac e shield. Polaris recommends wearing approved Personal Protec tive Equipment (PPE) bearing markings such as VESC 8, V -8, Z87.
14 Safety Operator Safety Operator Restrictions/Age Restrictions This vehicle is an ADUL T VEHICLE ONL Y . Op eration is prohibited for anyone under 16 years of age.
15 Safety Operator Safety Safety T raining A TV safety training is a top priority for Polaris. When you purchased yo ur new A TV , your dealer instructed you on the authorized A TV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your A TV .
16 Safety Operator Safety The following signal words and symbols appear throu ghout this manual an d on your vehicle. Y our safety is involve d when these words and symbols are used. Become familiar with their meanings before r eading the manual. The safe ty alert symbol , on your vehicl e or in this manual, alerts you to the potential for injury .
17 Safety Operator Safety • Read this manual and all labels carefully . Follow all operating procedures. • Never operate an A TV without proper instruction. T ak e a training course. Pu r- chasers of a new Polaris A TV a nd age eli- gible family members are entitled to take the A TV RiderCourse sm .
18 Safety Operator Safety • Never operate an A TV on a public street, road or highway , including a dirt or gravel road. • Never operate an A TV without wearing an approved helmet that fits properly . Always wear eye protection (gog gles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.
19 Safety Operator Safety • Never operate on excessively rough, slip- pery or loose terrain. • Always follow proper turning procedures as described in this manual. Practice turn- ing at low speeds before attempting to turn at faster speeds. Do not turn at e xces- sive speeds.
20 Safety Operator Safety • Always follow proper procedures for crossing the side of a hill. A void hills with excessively slippery or loose sur- faces. Shift your weight uphil l. Never attempt to turn th e A TV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.
21 Safety Operator Safety • Always be careful of skidding or sliding. On slippery surfaces like ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of con- trol. • Always check for obstacles before oper- ating in a new area.
22 Safety Operator Safety • Always check for obstacles or people behind the A TV before operating in reverse. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for your A TV , and always main- tain proper tire pressure.
23 Safety Operator Safety Equipment Modifications W e are concerned for the safety of our custom ers and for the general public. Therefore, we strongly recommend that consumers do not in st all on a Polaris A TV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
24 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV wi thout proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operato r does not know how to operate the A TV properly in diffe rent situations and on different types of terrain.
25 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to follow the skill and experience recommendation s for this A TV . WHA T CAN HAPPEN Severe injury and/or death could occur if a begi nner or inexp erienced driver operates this A TV .
26 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to follow the age recomme ndations for this A TV . WHA T CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age recommendation operates this A TV .
27 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Carrying a passe nger on an A TV . WHA T CAN HAPPEN Carrying a passenger greatly reduces the operator's ability to balance and control the A TV , which could cause an accide nt and injury to the operator and/or passenger .
28 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating an A TV on pave d surfaces, includin g sidewalks, paths, parking lots, and dri veways. WHA T CAN HAPPEN A TV tires are designed for off- road use. Operating on paved surfaces may adversely affect the hand ling of the A TV and could result in loss of control, accident, and/or injury .
29 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highways. WHA T CAN HAPPEN The A TV could collide with anothe r vehicle. HOW TO A VOID THE HAZARD Never operate the A TV on any pu blic street, road or highway , including dirt and gravel roads.
30 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating this A TV without wearin g an approved helmet, eye protection and protective clothing. WHA T CAN HAPPEN Operating an A T V without an approved helmet in creases the risk of a severe head injury or death in the event of an accident.
31 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV after consuming alcoh ol or drugs. WHA T CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and ope rator balance and perception could be affected.
32 Safety Operator Safety WARNING POTENTIAL HAZARD Operating the A TV at excessive speeds. WHA T CAN HAPPEN Excessive speed increases the operator's chance of losing control of the A TV , which can result in an accident causing severe injury or death.
33 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO A VOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving.
34 Safety Operator Safety WAR N I N G POTENTIAL HAZARD T owing or pulling an object behind th e A TV . WHA T CAN HAPPEN A wagon, sled or other obje ct towed behi nd an A TV does not have b rakes or steering. The object may overturn or collide with other objects and cause serious injuries.
35 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to use extra caution when operating the A TV on unfamiliar terrain. WHA T CAN HAPPEN Unfamiliar terrain may contain hid den rocks, bumps, or holes that could cause loss of control or overtu rn.
36 Safety Operator Safety WAR N I N G POTENTIAL HAZARD F ai lure to use extra caution when operati ng on excessively rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on excessively rough , slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.
37 Safety Operator Safety WARNING POTENTIAL HAZARD T urning improperl y . WHA T CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual.
38 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Removing hands from the handlebars or feet from the footpegs during operation. WHA T CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the A TV .
39 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating on exce ssively steep hil ls. WHA T CAN HAPPEN The vehicle may overturn. HOW TO A VOID THE HAZARD Never operate on hills too steep for the A TV or for your abilities. Never operate the A TV on hills steeper than 25 degrees 25 ° .
40 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Climbing hills improperly . WHA T CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for climbing hills as describe d in the Owner's Manual beginning on page 82.
41 Safety Operator Safety WAR N I N G POTENTIAL HAZARD T r aveling downhill improperly . WHA T CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO A VOID THE HAZARD Always follow proper procedures for traveling down hill s as described in the owner's manual.
42 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHA T CAN HAPPEN Improperly crossing or turning as hills could cause lo ss of control or overturn.
43 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Stalling, rolling backwards or improperly dismountin g while climbing a hill. WHA T CAN HAPPEN The vehicle could overturn. HOW TO A VOID THE HAZARD Maintain steady speed when climbing a hill If all forward speed is lost: Keep your weight uphill.
44 Safety Operator Safety WARNING POTENTIAL HAZARD Skidding or sliding. WHA T CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly , the A TV could overturn.
45 Safety Operator Safety WARNING POTENTIAL HAZARD Operating on frozen b odies of water . WHA T CAN HAPPEN Severe injury or death can result if the A TV and/or the operator fall through the ice. HOW TO A VOID THE HAZARD Never operate the A TV on a fro zen body of water .
46 Safety Operator Safety WAR N I N G POTENTIAL HAZARD Operating the A TV through deep or fast-flowin g water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO A VOID THE HAZARD Avoid operating the A TV through deep or fast-flowin g water .
47 Safety Operator Safety WARNING POTENTIAL HAZARD Overloading the A TV or carrying/towing cargo. WHA T CAN HAPPEN Overloading or carrying/towing cargo can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO A VOID THE HAZARD Never haul cargo or tow a load with this A TV .
48 Safety Operator Safety WARNING Safe operation of this rider -active vehicle requires good judge ment and physical skills. Persons with cognitive or physical disabili ties who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or de ath.
49 Safety Operator Safety WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
50 F eatures and Controls Start Button Engine Stop Switch Main Key Switch.
51 F eatures and Controls Main K ey Switch The main key switch must be in the RUN position to start the engine. See page 75 for starting procedures. Start Button Press the start button to engage the starter . Alwa ys release the start button promptly w hen the engine starts.
52 F eatures and Controls Lights Indicator Lights An illuminated light in the indicator window will alert you to the follow- ing conditions. • Hot engin e • Reverse gear is selected • Neutral gear is selected NOTE: If indicator lights fail to oper- ate, check connections.
53 F eatures and Controls Lights Headlights Use the light switch to turn the lights on and off and to switch the lights from high beam to low beam. NOTE: The lights won't work unless the key is in the ON position and the engine stop switch is in the RUN position.
54 F eatures and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar . Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears. The clutch is self-adjusting, but lever position can be changed to fit the operator’ s hand.
55 F eatures and Controls Clutch Fluid The clutch fluid master cylinder is located on the left handlebar . Check the fluid level in the reservoir before each ride. The level should be 4mm below the upper edge of the re servoir . Do not overfill. Polaris recommends the use of KTM Hydraulic Clutch Oil.
56 F eatures and Controls Throttle Lever The throttle lever is loca ted on the right handlebar . Squeeze the lever toward the handlebar to increase engine speed and ve hicle movement. Engine speed returns to idle when the leve r is released. See page 155 for throttle adjustment procedures.
57 F eatures and Controls Throttle Lever This A TV is equipped with an Electronic Th rottle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open posi- tion when the operator re leases the throttle lever , the engine will stop.
58 F eatures and Controls Foot Brake The foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. If the rear wheels slide wh ile using the foot brake, reduce brake pedal pressure to brake the wheels without skidding.
59 F eatures and Controls Hand Brake The hand brake operates the front brakes. The hand brake is located on the right handlebar . Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes.
60 F eatures and Controls Master Cylinder/Brake Fluid Under normal operation, the diap hragm extends in to the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced.
61 F eatures and Controls Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder be fore each ride. If the fluid level is low add DOT 4 brake fluid only .
62 F eatures and Controls Pa r k i n g B r a k e 1. Place the transmission in first gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock down to engage the lock . Release the brake lever .
63 F eatures and Controls Pa r k i n g B r a k e Important Safeguards • The parking brake may relax if left o n for a long period of time. Alway s block the wheels to prevent rolling. • Always block the wheels on the downhill side of the A TV if leaving it parked on a hill.
64 F eatures and Controls Manual Shift Shift P edal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the tr ansmission to the next gear in the shifting sequence. The pedal automa tically returns to a horizontal position when released.
65 F eatures and Controls Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gea rs. 1. When starting from a stopped p osition, place the transmission in neutral. 2. Squeeze and hold the brake lever . NOTE: Do not squeeze the throttle lever .
66 F eatures and Controls Manual Shift Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse unintentionally . 1. Place the transmission in first gear . See page 64. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission.
67 F eatures and Controls Manual Shift Deceleration T o slow or stop the vehicle , release the thro ttle lever and apply the brakes smoothly and evenly . As the vehicle slows and engine RPM de creases, disengage the clutch and shift to a lower gear . NOTE: Be sure the engine RPM has sufficiently decreased before shifting to a lower gear .
68 F eatures and Controls Choke The choke assists in starting a cold engine. The choke knob is located on the left side of the carburetor . Refer to the engine starting procedure on page 75 for correct choke and throttle settings during starting. Fu e l T a n k The fuel tank filler cap is located directly below the handlebar .
69 F eatures and Controls F uel V a lve The fuel valve is located on the left side of the A TV . It has three positions: OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main suppl y is exhausted. NOTE: There's about a 5 to 8 mile (8 to 13 km) range on reserve gas.
70 Break-In P eriod Careful treatment of a new engine and transmis sion will result in more efficient performance and longer life for both. The b reak-in period for your new Polaris A TV is the first three hours of operation, or the time it takes to use 5-6 ga llons (20 liters) of fuel .
71 Break-In Period 1. Fill the fuel tank with gasoline. See page 74. 2. Check the oil level. Ad d the recommended oil as needed to maintain the oil level i n the proper range. See page 109. 3. Allow the engine suf ficient time to warm up before operating.
72 Pre-Ride Inspection WAR N I N G If a proper inspection is not done before each us e, severe injury or dea th could result. Always inspect the vehicle before ea ch use to ensu re it's in proper operating co ndition.
73 Pre-Ride Inspection Pre-Ride Checklis t P age Coolant (if applicable) Ensure proper level 119 Coolant hoses (if applica ble) Inspect for leaks -- Throttle Ensure smooth operation 56 Indicator light.
74 Operation F uel System WAR N I N G Gasoline is h ighly flammable and e xplosive under certain con ditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel with the engine stopped, and outd oors or in a well ventilated area.
75 Operation Starting the Engine The engine can be starte d when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. NOTE: Fuel is injected into the intake passage each time the throttle lever is depressed.
76 Operation Starting the Engine 1. Shift the transmission to neutral. 2. Lock the parking brake. 3. T u rn the fuel valve on. 4. Sit on the vehicle. 5. Disengage the clutch. 6. If the engine is cold, pull the choke knob out until it stops. Do not use the choke if starting a warm engine.
77 Operation Starting the Engine NOTE: If starting the engi ne while in gear , apply the hand b rake and squeeze th e clutch lever fully to disengage the clutch. If starting the engine wh ile in neutral , the neutral indicator li ght should be on. If it isn't, disengage the clutch and shift the foot pedal to find neutral.
78 Operation Driving Procedure 1. Sit upright with both feet on the footpegs and both hands on the h andlebars. 2. Star t the engine and allow it to warm up. 3. Shift the transmission into gear . See page 64. 4. Check your surroun dings and determine your path of travel.
79 Operation Making T urns Practice making turns at slow speeds befo re attempting to turn at faster speeds. Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times.
80 Operation Driving on Slippery Surfaces WAR N I N G F ai lure to exercise care when operating on slippery su rfaces can result in loss of tire traction and cause loss of control, acciden t, and serious injury or death . Never apply the brakes during a skid.
81 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sh arp turns, which can cause skids.
82 Operation Driving Uphill WAR N I N G Braking and handling are greatly affecte d when oper ating in hilly terrain . Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (25 ° max imum).
83 Operation Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void steep hills (25 ° maximum). 3. Keep both feet on the footpegs . 4. T ransfer your weight forward. 5. Proceed at a ste ady rate of speed and throttle opening.
84 Operation Driving Across Hillsides WAR N I N G Improperly crossing hills or turning on hills can resu l t in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.
85 Operation Driving Across Hillsides If you enter into a situation where sidehilli ng is unavoidable, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keep- ing your feet on the footpe gs.
86 Operation T urning Around on a Hill If the vehicle stalls while climbi ng a hill, never back it down th e hill! One maneuver that can be used when it's necessary to turn around while clim bing a hill is the K-turn: 1. Keep your body weight uphill.
87 Operation T urning Around on a Hill 6. Reach across th e handlebar and appl y the front brakes to unloc k the parking brake. 7. W ith the front brakes applied, pull in the clutch lever . Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.
88 Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. T ra nsfer your weight to the rear of the vehicle. 3. Slow down. 4. Shift to the lowest gear possible while maintaining a safe speed. 5.
89 Operation P arking on a Hill or Incline A void parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions: 1. T u rn the engine off. 2. Place the transmission in first gear . 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
90 Operation Driving Through W ater Y our A TV can operate through water with a maximum recommended depth equ al to the level of the footpegs. Follow these proce- dures when operating through water: 1. Determine water depths and current before crossing.
91 Operation Driving Through W ater A void operating your A TV through deep or fast flowing water . If the A TV is operated in deeper water th an recommended , it's critical to have it servic ed as outlined in the mainte- nance chart beginning on page 97.
92 Operation Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the bra kes lightly for stopping. 3. A void turning at sharp ang les. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing.
93 Operation Driving in Reverse This Polaris A TV is equipped with a reverse sp eed limiter . Do not oper ate at full throttle. Use just enough throttle to maintain a desired speed. WAR N I N G F ai lure to use ca ution when operating in reverse can result in se rious injury or de ath.
94 Operation Driving Over Obstacles Be alert! Look ah ead and learn to re ad the ter- rain you're traveling on . Be constantly alert for hazards such as logs, rocks and low hang- ing branches. WARNING Severe injury or death ca n result if your vehicle comes in contact with a hidden obstacle.
95 Emission Control Systems Noise Emission Control System Do not modify the engine, intake or ex haust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requ ire- ments. Operation on Public Lands in the U.
96 Emission Control Systems Crankcase Emission Control System This engine is equipped with a closed cran kcase system. Blow-by gases are forced back to the combustion chamber by the intake system.
97 Maintenanc e Periodic Maintenance Chart Routine inspection and service are critical to the performance and rel iability of your high performance engine.
98 Maintenance Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer . Record maintenance and service in the Main tenance Log beginning on page 209.
99 Maintenanc e Periodic Maintenance Chart Maintenance Chart K ey X Perform these operations mo re often under severe use. E Emission-related service (Failure to condu ct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services.
100 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used Brake systems/brake fluid -- Pre-ride -- Check each day before operating the vehicle. Make adjustments as needed.
101 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these ser.
102 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons (liters) Brake pad wear 10 Monthly -- Inspect regul.
103 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these ser.
104 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) X z Upper steering post (1) 45 6 M -- Inspect; tight.
105 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these ser.
106 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) E Compression ring 90 -- 156 (600) See your dealer o.
107 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these ser.
108 Maintenance Engine Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Periodi c Maintenance Chart beginning on page 97 .
109 Maintenanc e Engine Oil Level Check the oil level before each use of the vehi- cle. If the engine is cold , the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible between the 1/2 and 3/4 levels in the sight glass.
110 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 97. Perform the initial break-in oil change after the fi rst three hours of operation. Always change both oil filters and clea n the oil screens whenever changing oil.
111 Maintenanc e Engine Oil Change 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to idle for two to three minutes. S top the en gine. 3. Place a drain pan beneath the crankcase. Remo ve the drain plug. Allow the oil to drain completely .
112 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Hex Plug View from bottom of vehicle Fr o n t.
113 Maintenanc e Engine Oil Change Cleaning the Short Oil Screen 1. Insert a hex key into the pl ug at the botto m of the engine. See illustration on preceding page. 2. Using a hammer , tap lightly on the key a few times to loosen the seal. Remove the plug.
114 Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen plug , located on the side of the engine near the engine number . 2. Remove the oil screen. Clean the screen thoroughly and blow with compressed air . 3. Check the O-rings.
115 Maintenanc e Engine Oil Change Cleaning the Long Oil Screen 5. Insert the tool through th e op ening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. 6. Reinstall the plug.
116 Maintenance Engine Oil Change Changing Oil Filters 1. Place a drain pan under the engine. 2. Remove the four oil filter cover screws (1). Remove the co vers. 3. Using circle clip (sna p ring) pliers, pull the oil filter inserts (2) out of the housing.
117 Maintenanc e Engine Oil Change Changing Oil Filters 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. T ighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fi ll plug (4). Add 40 oz. (1.2 liters) of the recommended engine oil (see page 108).
118 Maintenance Engine Cooling System The engine coolant level is cont rolled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck , radiator pressure cap and connecting hose.
119 Maintenanc e Engine Cooling System Coolant Level The recovery bottle is locat ed on the right side of the vehicle under the front fend er . The fluid level must be maintained be tween the FULL and ADD marks on the side panel (when the fl uid is cool).
120 Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dr y , inspect the level in the radiator and add coolant if n ecessary . The radiator pressure cap is located on the left side of the vehicle. 1. Remove the pre ssure cap.
121 Maintenanc e Engine Cooling System Cooling System Bleeding Bleeding the cooling system is required only if the syst em has been drained for maintenance and/or repair . Always allow the engine to cool sufficiently before removing the radiator pres- sure cap.
122 Maintenance Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover . 3. Remove the wing nuts securi ng the filter to the airbox. 4. Pull the filter assembly out of the air box. Note the placement of th e rubber ring for rein- stallation.
123 Maintenanc e Carburetor Normal wear from engine vib rations may cause th e carburetor to supply an overly rich fuel mixture. Replace the jet needle and the need le jet after every 180 hours of operation. Idle Speed Carburetor idle adjustments affect engine star t ing behavior .
124 Maintenance Carburetor Idle Speed 1. Position the vehicle on a level surface. 2. Lock the parking brake. Place the transmission in neutral. 3. Star t the engine and allow it to idle for five min- utes, or until operating temperature is reached. 4.
125 Maintenanc e Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be ginni ng on page 97. Al ways drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool.
126 Maintenance Carburetor Jetting Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes an d temperatures, certain adjust- ments can be made to improve its operation and driveabilit y .
127 Maintenanc e Lights When servicing a halogen lamp, do n't touch the lamp with bare fingers. Oil from y our skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WAR N I N G Poor lighting while driving can result in severe in jury or death.
128 Maintenance Lights Headlight Adjustment 1. Position the vehicle on a level surface with the head- light approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from th e floor to the center of the headlight and make a mark on the wall at the same height.
129 Maintenanc e Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counter clockwise to remove the bulb. On the right headlamp, turn the bulb housing clockwise to remove the bulb.
130 Maintenance Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights. 2. Remove the front cab (see pa ge 133). 3. Remove the small adjuster bracket. Install it on the new lamp. 4. Remove the large pivot bracket and remove the headlamp.
131 Maintenanc e Lights Headlight Assembly Replacement 6. Install the adjuster bracket onto the inboa rd pivot pin of the headlamp. Adjust for approximately 1/16" clearance between the bracket and the edge of the headlight. T ighten the mounting screws.
132 Maintenance Lights Brake Light Adjustment If your model is equipped with a me chanical brake light switch, perform the following procedure to check the rear brake light for proper opera tion before each use of the vehicle. 1. T urn the ignition key on.
133 Maintenanc e F ro nt Cab Removal 1. Remove the left and right cab moun t screws (1). 2. Remove the wire harness connector from the cab. The connec tor is located under the left fender . 3. Remove the fuel tank cover screws (2). 4. Remove the four side panel screws (3).
134 Maintenance Side P a nel Removal 1. Unlatch and remove the sea t. Remove the front cab. 2. Remove the two screws securing the side panel. 3. Remove the sid e panel. Rear Cab Removal 1. Unlatch and remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab.
135 Maintenanc e Spark Plugs Refer to the specifications section begin ning on page 182 for recommended spark plug type and gap. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up an d the vehicle has been driven at high er speeds.
136 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
137 Maintenanc e Spark Plugs Spark Plug Removal 1. Access the spark plug at the right s ide of the engine. 2. Using the spark plug socket and a wrench, rotate counterclockwise to remove the spark plug. 3. After reinstalling the spark plug, torque to 14 ft.
138 Maintenance Spark Arrestor Clean-Out T o remove a ccumulated carbon, clean the spark arrestor at the interv als recommended in the Periodic Maintenance Char t beginning on page 97. WAR N I N G F ai lure to heed these warnings could result in serious injury or de ath.
139 Maintenanc e Spark Arrestor Clean-Out Periodically clean the spark arrestor to remove accumulated carbon. 1. Remove the retaining screw and remove the arrestor from the end of the muf fler . 2. Use a non-syn thetic brush to clean the arrestor screen.
140 Maintenance V ehicle Immersion If your A TV has been subm erged or overturned in water deeper than th e footpeg level, it's critical to dry it promptly and prop erly before starting the engine.
141 Maintenanc e V ehicle Immersion 1. T u rn the fuel valve off. 2. Drain water from the air box and clean the air filter . See page 122. 3. Drain the carburetor bowl.
142 Maintenance V ehicle Immersion 6. Press and hold the starter button for 10 sec ond intervals for about one minute or until water vapor is no longer ejec ting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride insp ection level, water has entered the crankcase.
143 Maintenanc e Battery The sealed b attery is alread y filled with el ectr olyte and has been sealed and fully charged at the factory . Never pry the sealing strip of f or add any other fluid to this battery . Keep the battery terminals and connections free of corrosion.
144 Maintenance Battery Storage Whenever the vehicle is not used for a period of three months or more, remov e the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
145 Maintenanc e Battery Installation NOTE: Always install a fully cha rged battery . Using a n ew battery that has not been fully cha rged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary , use a .
146 Maintenance Battery Charging (Sealed Battery) On a sealed battery , the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully char ged battery will register 12.8 V or h igher . If the voltage is less than 12.
147 Maintenanc e Battery Charging (Sealed Battery) NOTE: The Polaris Battery T ender battery charge r can be left connected durin g the storage period and will automatically charge the batte ry if th e voltage drops below a p re-determined point. NOTE: If the battery fails to recharge during vehicle operatio n, check voltage regulator connections.
148 Maintenance Battery Charging (Sealed Battery) NOTE: Always verify battery condit ion before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.
149 Maintenanc e Tires Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. WAR N I N G Operating your A TV with worn ti res, improperly inflated tires, non-stand ard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.
150 Maintenance Wheel Nut T orque Specifications Check the wheel nut torques occasionally and wh en they've been loo sened for maintenance. Wheel Hub Tightening Front wheel bearing tightness an d spindle nut retention are cr itical componen t operations.
151 Maintenanc e Wheel Installation 1. Place the transmission in gear . Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. 3. Install the wheel bolts and finger tighten them.
152 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Main tenance Chart beginning on page 97. Always bleed the clutch system any time the clutch lever feels unrespo nsive. Always use the recommended fluid when blee ding the clutch system.
153 Maintenanc e Clutch System Bleeding 4. Remove the bleeder screw (2) from the slave cylinder . 5. Press fluid into the system unti l the fluid runs out of the hole (3) in the master cylinder without producing bub bles. NOTE: Extract fluid from the ma ster cylinder during the process to preven t overflowin g.
154 Maintenance Throttle Lever F reeplay Periodically check throttle lever freeplay . Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are need ed, use the procedure on page 155.
155 Maintenanc e Throttle Cable F r eeplay Adjustment 1. Locate the throttle cable at the handlebar . 2. Slide the boots off th e inline cable adjuster sleeve and loosen the locking nut. 3. T urn the adjuster until 1/16" to 1/8" (1.5-3 mm) freeplay is achieved at the thumb lever .
156 Maintenance Brakes Both brakes are self-adjusting, but the following checks are recomme nded to keep the brake systems in good operating condition. Check more often if brakes are used heavily under nor- mal operation. WAR N I N G An over -full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death.
157 Maintenanc e Brakes 1. Always maintain brake fluid at the recommended level. See pages 60-61. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear , damage and loose ness.
158 Maintenance T oe Alignment Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a ne utral toe setting. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahe ad po sition.
159 Maintenanc e T oe Alignment 3. T ie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of t he rear tire. NOTE: If available, yo u may use a lo ng straight-edge instead of string.
160 Maintenance Chain T ension Inspection Check the amount of cha in slack by moving the vehicle slightly forwa rd to remove slack at the top side of th e chain. NOTE: The chain has a press-on master link. A chain tool must be used if it's necessary to remove the chain for ser vice.
161 Maintenanc e Chain T ension Inspection 1. Collapse the suspension w ith an adjustable (buckle type) tr ailer tie down strap (1). Fas- ten the strap around the axle and rear bumper tube. 2. T ighten the strap until a straight line (2) can be drawn from the axle to the t ransmission output shaft, intersecting the swing arm pivo t.
162 Maintenance Chain T ension Adjustment 1. Loosen the two eccentric locking bolts. NOTE: Refer to the illustration on the following page. 2. Insert a pin punch into the eccentric axle housing. 3. Roll the vehicle slightly to adjust chain slack to the proper dimension.
163 Maintenanc e Chain T ension Adjustment Step 1 Step 2 Proper splicelink clip opening position.
164 Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Loosen the four handlebar bo lts. 2. Adjust the handlebar to the desired height. Be sure the handlebars do no t contact the gas tank or any other p art of the machine when turned fully to the left or right.
165 Maintenanc e Steering Inspection Check the steering assembly periodically for loos e nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the stee ring post, see your Polaris dealer for service before operating the vehicle.
166 Maintenance Suspension Settings Use a flat -blade screwd river to make d amping adjustm ents. NOTE: When the adjuster screw is turned clockwise until it stops, the damping is in the fully closed position.
167 Maintenanc e F ront Suspension Compression Damping (Limited Edition) T o adjust the front suspension compression damping, use the adjustment proc edures outlined for the rear suspension compression damping on page 171. Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight.
168 Maintenance F ront Susp ension Spring Preload 1. Raise an d safely suppo rt the front of the vehicle of f the ground to allo w the suspension to fully extend. 2. T u rn the adjuster to the le ft (1) to increase preload for a stiffer ride. T urn the adjuster to the right (2) to decrease preload for a softer ride.
169 Maintenanc e Rear Suspension The rear suspension spring preload, shock rebound damp ing and shock compression dampin g may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the vehicle off the ground to allow the suspen sion to fully extend.
170 Maintenance Rear Suspension Rebound Damping Use a flat -blade screwd river to make d amping adjustm ents. 1. Locate the rebound dam ping clicker drum between the lower spring seat and the lower shock mount. 2. T u rn the clicker counter-clockwise (1) to decrease the rebound damping.
171 Maintenanc e Rear Suspension Compression Damping Use a flat -blade screwd river to make d amping adjust- ments. The compressio n damping clicker is loca ted on top of the shock reservo ir , under the right rear fender . T u rn the clicker clockwise (1) to increase compression damping.
172 Maintenance Cleaning Keeping your vehicle clean will not only impr ove its appearance but it can also extend the life of various components. CA UTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap.
173 Maintenanc e Cleaning W ashing the V ehicle The best and safest way to clean your Polaris ve hicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing cloth, cleani ng the upper body first and the lower parts last.
174 Maintenance Cleaning W ashing the V ehicle Wa shing Tips • A void the use of harsh cleaners, which can scratch the finish. • Do not use a power washer to clean the vehicle. • Do not use medium to heavy duty compounds on the finish. • Always use clean cloths and pads for cleaning and pol ishing.
175 Maintenanc e Cleaning W ashing the V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage compo nents and could remove paint an d decals.
176 Maintenance Pol i s hi n g Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Fo llow the instructions on the container . Polishing Tips • A void the use of automotive products, some of which can scratch the finish of your v ehi- cle.
177 Maintenanc e Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 172. Battery Storage Refer to pages 143-148 for ba ttery storage and battery charging pro cedures. CA UTION Starting the engi ne during the storage period will di sturb the p rotective fil m created by fogging and damage could occur .
178 Maintenance Storage Engine Oil Change the oil and both filters. Clean the oil screens. See page 1 10. Air Filter / Air Box Inspect and clean (or replace) the air filter . Clean the air box. Drai n the sediment tube. Fluid Levels Inspect fluid levels.
179 Maintenanc e Storage Stabilize the F uel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel S tabilizer . Follow the instruc- tions on the container for t he recommended amount.
180 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on pa ge 97. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated.
181 Maintenanc e T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in first gear . 3. Lock the parking brake. 4. Remove the key to preven t loss during transporting. 5. Secure the fuel cap, oil cap and seat.
182 Specifications Outlaw 450 S Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet See your owner’s manual supplement or your Polaris dealer Dry Weight 365 lbs./166 kg Main Jet F uel Capacity 3.9 gal./14.8 l Needle Jet Overall Length 71.5 in./182 cm Jet Needle Overall Width 47 in.
183 Specifications Outlaw 450 S Jetting Chart Please see your owner’ s manual supplement or your Polaris dealer fo r jetting information. Outlaw 450 S Driving System T ype Rear T wo- Wheel Drive Tire Size - Front 20 x 6R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 18 x 10R9 Primary Ratio 2.
184 Specifications Outlaw 525 S Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet #45 Dry Weight 375 lbs./170 kg Main Jet #138 F uel Capacity 3.9 gal./14.8 l Clip Position 4 Overall Length 71.5 in./182 cm Jet Needle OBDVS Overall Width 47.5 in./121 cm Alternator Output 200 w @ 3000 RPM Overall Height 45 in.
185 Specifications Outlaw 525 S Jetting Chart Outlaw 525 S Driving System T ype Rear T wo- Wheel Drive Tire Size - Front 21 x 7R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 20 x 11R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.
186 P olaris Products P art Number Desc ription Engine Lubr icant 2876244 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (gal.) Grease / Specia lized Lubricants 2871312 Grease Gun Kit, Pre mium All Season (3 oz.
187 P olaris Products P art Number Descr iption Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Bra ke Fluid (12 oz.) 2876335 Hydraulic C lutch Oil (qt.
188 T roubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine T urns Over , F ails to Start Possible Caus e Solution Out of fuel T urn the.
189 T r oubleshooting Engine T urns Over , F ails to Start Possible Caus e Solution No spark to spark plug Inspect, clean and/or replace spark plugs See your Polaris dealer Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart.
190 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Cause Solution Fuseable link See Polari s dealer for replacement Low battery voltage Rechar ge battery to 12.
191 T r oubleshooting Engine Backfires Possible Cause Solution W eak, fouled or defective spark plug In spect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs .
192 T roubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspec t, clean and/or replace spark plug W orn or defective spark pl ug wire S.
193 T r oubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Cause Solution Clogged air filter Inspect and clean or replace Electronic throttle control ma lfunction See your Polaris dea.
194 T roubleshooting Engine Runs Irregularly , Stalls or Misfires Possible Lean F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean the fuel system Low octane fuel Replace.
195 T r oubleshooting Engine F ails to Reach High RPM Engine Uses Excessive Oil Possible Cause Solution W orn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets T ighten jet.
196 T roubleshooting Engine Stops or Loses P ower Possible Cause Solution Out of fuel T urn the fuel valve to reserve, ref uel Interrupted fuel supply Clean fuel system and carburetor Clogged, dirty o.
197 T r oubleshooting Engine Stops or Loses P ower Possible Cause Solution Kinked or plugged fuel vent line Inspect and replace W ater present in fuel Replace with new fuel Overuse of choke Ins pect, .
198 T roubleshooting Engine Overheats Possible Cause Solution Debris lodged in screen Re move and clean the screen Plugged radiator Use a garden hose to flush any debris from the radia- tor fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency .
199 T r oubleshooting Engine F ails to Reach F ull Power Possible Cause Solution Interrupted fuel supply Clean fuel system and carburetor Float leak s Replace t he float Clogged, dirty or wet air filt.
200 W arranty LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehi cle (A TV) agai nst defe cts in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
201 W arranty WARRANTY COVERAGE AND EXCL U SIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris limi ted warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accident al damage, normal wear and tear, a buse or improper ha ndling.
202 W arranty WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLU DING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD.
203 W arranty HOW TO OBT AIN WARRANTY SERVICE If your A TV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris A TVs. When requesting warranty service you mu st present your copy of the W arranty Registration form to the dealer .
204 W arranty EXPORTED VEHICLES EXCEP T WHERE SP ECIFICALL Y REQUIRE D BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA TIO N. This policy does not apply to vehicles that have received authorization for export from Po laris Industries.
205 W arranty EXPORTED VEHICLES How to Get Servic e I n the country wh ere your vehi cle was purchase d: W arranty or Service Bulletin repairs must be done by an authorized Polar is dealer .
206 W arranty EXPORTED VEHICLES How to Get Servic e If Purchased From A Private Party: If you purchase a Polaris product from a pr ivate citizen out side of the country in whic h the vehicle was originally purchased, all warranty cove rage will be denied.
207 W arranty U.S.A. EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polar is standard limite d warranty for this vehicle.
208 W arranty U.S.A. EP A Emissions Limited W arranty The exclusive remedy for bre ach of this limited warranty shall be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products.
209 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced . This will provide you and future owners with an accurate log of maintenance and services performed.
210 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 60 90.
211 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS.
212 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS.
213 Index A Age Restrictions . . . . . . . . . . . . . 14 Air Filter Systems . . . . . . . . . . . . 122 B Battery Charging . . . . . . . . . . . . 146-148 Installation . . . . . . . . . . . . . 145 Maintenance . . . . . . . . . . . . 143 Removal . . .
214 Index F Fluid Brake . . . . . . . . . . . . . . . . 60-61 Clutch . . . . . . . . . . . . . . . . . . 55 Foot Brake . . . . . . . . . . . . . . . . . . . 58 Foot Brake Fluid Lev el . . . . . . . . . 61 Fuel Filter . . . . . . . . . . . . . . . . . .
215 Index S Safety Decals Age 16 Warning . . . . . . . . . . 10 Discretionary War ning . . . . . 10 General Warnin g . . . . . . . . . . 9 No Passenger Warning . . . . . 11 Sport ATV Warnin g. . . . . . . 10 Tire Pressure/Load Warning 11 Safety Trainin g .
An important point after buying a device Polaris 525 S (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 525 S yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 525 S - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 525 S you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 525 S will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 525 S, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 525 S.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 525 S. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 525 S along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
