Category:
Performance ATV
Target Audience:
Owners, Technicians, Enthusiasts
Competitors:
Yamaha Raptor, Suzuki LT-R450, Kawasaki KFX450R
Manual Advantage:
Instant digital access, printable pages, lifetime replacement policy, cost-effective alternative to paper manuals.
Vehicle Focus:
High-performance sport ATV with IRS (Independent Rear Suspension) on specific models.
Primary Coverage:
Repair, Maintenance, Troubleshooting
Secondary Coverage:
Parts identification (implied via common manual content)
Estimated Page Count:
Variable (Digital download, typically 300-600+ pages for comprehensive ATV manuals)
Type:
Service/Repair Manual
Format:
PDF (Electronic Downloadable)
Engine:
Yes (including removal/installation, specifications, cooling, lubrication)
Fuel System:
Yes (carburetor/injection diagnostics, fuel pump, lines)
Transmission Drivetrain:
Yes (drive chain, sprockets, clutch)
Steering:
Yes (steering system components, linkage, alignment)
Suspension:
Yes (shocks, A-arms, bearings)
Electrical System:
Yes (wiring diagrams, ignition, lighting, charging)
Bodywork Chassis:
Yes (body panels, frame, seat, handlebars)
Brakes:
Implied (standard for comprehensive repair manuals)
Wheels Tires:
Implied (standard for comprehensive repair manuals)
Routine Maintenance:
Yes (oil changes, filter replacements, lubrication, chain adjustment)
Troubleshooting:
Yes (advanced troubleshooting section listed)
Component Rebuilds:
Yes (engine, transmission, shocks expected)
Diagnostic Procedures:
Yes (implied by troubleshooting)
Depth:
Comprehensive (Covers routine maintenance to advanced repairs and diagnostics)
Engine Type 450:
Single-cylinder, 4-stroke (Likely DOHC, liquid-cooled)
Engine Displacement 450:
Approximately 449cc (Specifics within manual)
Engine Type 525:
Single-cylinder, 4-stroke (Likely DOHC, liquid-cooled)
Engine Displacement 525:
Approximately 510cc (Specifics within manual)
Horsepower Range:
Estimated 40-50 HP (Varies by specific model and tune, detailed in manual)
Torque Range:
Estimated 30-38 lb-ft (Varies by specific model, detailed in manual)
Fuel Delivery:
Carbureted or Fuel Injection (Likely Keihin carburetors for this era, FI on later models/variants, manual will specify)
Fuel Type:
Unleaded Gasoline (91+ Octane Recommended)
Cooling Method:
Liquid-cooled
Oil Type Recommendation:
SAE 10W-40 Motorcycle Specific (API SG or higher, detailed in manual)
Length:
Approx. 71.6 inches (181.9 cm) - Varies slightly by model, detailed in manual
Width:
Approx. 47.7 inches (121.2 cm) - Varies slightly by model, detailed in manual
Height:
Approx. 44.9 inches (114.0 cm) - Varies slightly by model, detailed in manual
Dry Weight:
Approx. 375-400 lbs (170-181 kg) - Varies by model, detailed in manual
Fuel Capacity:
3.2 gal (12.1 L) (Check manual for exact spec)
Front Tire Size:
22x7-10 or 21x7-10 (varies by model, specified in manual)
Rear Tire Size:
20x10-9 or 22x10-9 (IRS models) (varies by model, specified in manual)
Wheel Bolt Pattern:
4/110 (Common for Polaris sport ATVs, confirm in manual)
Safety Standards:
Designed to meet ANSI standards for ATVs (specified in manual)
Braking System:
Hydraulic Disc Brakes (Front and Rear - specific caliper counts and rotor sizes in manual)
Parking Brake:
Yes (Hand or foot actuated, manual will detail)
Rollover Protection:
N/A (Standard ATV design)
Throttle Limiter:
Possible (often for training models, but unlikely on this performance model; check manual)
Display:
Digital LCD Display (Speedometer, Odometer, Trip Meter, Clock, Neutral Indicator, High Beam Indicator)
Charging Port:
Likely 12V accessory outlet (for charging GPS or phone, check manual)
Oil Change Interval:
Every 100 hours or 12 months (Recommended, verify in manual for specific conditions)
Air Filter Cleaning:
Inspect every 25 hours, clean as needed (more frequently in dusty conditions)
Spark Plug Replacement:
Check and gap every 100 hours, replace as needed (Specific plug type in manual)
Engine Oil Specification:
SAE 10W-40 Motorcycle Synthetic Blend or Full Synthetic (API SG or higher)
Coolant Type:
Ethylene Glycol based Antifreeze/Coolant (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Common Wear Items:
Wheel bearings, tie rod ends, drive chain/sprockets, brake pads, ball joints (especially on IRS models with heavy use).
Engine Performance Concerns:
Carburetor tuning can be sensitive to altitude and temperature; check for vacuum leaks or fuel delivery issues if performance drops.
Brand Origin:
American manufacturer, known for ATVs and snowmobiles.
Outlaw Lineage:
The Outlaw series represented Polaris's foray into the sport ATV market, competing with established brands. The IRS models offered improved comfort and handling over traditional solid rear axle setups.
Manufacturing Location:
USA (Typically Roseau, Minnesota)