2008 Polaris Outlaw 450 MXR / 525 S / IRS Service Manual
Technician-level documentation for 2008 Polaris Outlaw 450 MXR, Outlaw 525 S, and Outlaw 525 IRS ATVs. Publication A08GJ45AA.
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Sample pages from the 2008 Polaris Outlaw 450 MXR / 525 S / IRS Service Manual manual
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Models Covered & Key Technical Specifications
Practical Operations Reference Manual: ATV Polaris Outlaw 450 MXR, Outlaw 525 S, Outlaw 525 IRS - Tough-Terrain Service Manual & Maintenance (2008) Field-Reference Engine-Type: KTM Liquid-cooled, single cylinder, SOHC, 4-stroke, 5-Speed Manual // Operational-Framework: Engine Model ES045KLE012, ES051KLE012, ES051KLE013 // Engine-Type: 448cc / 510cc, 1-cylinder
- Established Capacity: 448 cc is the standard engine displacement for the Outlaw 450 MXR Unit.
- Operational Dimensions: 71.5 in. / 182 cm defines the overall length of all models.
- Essential Power Rating: 200W @ 3000 RPM signifies the alternator output Capability.
- Baseline Specifications: 11:1 is the standard compression ratio for all models Architecture.
- Approved Torque Values: 15 ft. lbs. (20 Nm) is the specified torque for the engine oil drain plug Threshold.
- Measured System Capacity: 2.25 qts. / 2.1 ltr indicates the coolant capacity for all models Standards.
Professional Workshop Service Manual & Technical Specifications
Practical Operations Reference Manual: ATV Polaris Outlaw 450 MXR, Outlaw 525 S, Outlaw 525 IRS - Tough-Terrain Service Manual & Maintenance (2008) Field-Reference
Engine-Type: KTM Liquid-cooled, single cylinder, SOHC, 4-stroke, 5-Speed Manual // Operational-Framework: Engine Model ES045KLE012, ES051KLE012, ES051KLE013 // Engine-Type: 448cc / 510cc, 1-cylinder
| Integrated-Framework | Rating | Context |
|---|---|---|
| Vehicle Identification | 2008 | Outlaw 450 MXR / 525 S / IRS |
| Engine Model | ES045KLE012, ES051KLE012, ES051KLE013 | Liquid-cooled, SOHC, 4-stroke, 5-Speed Manual |
| Vehicle Identification | A08GJ45AA, A08GJ52AA, A08GP52AA | MXR, S, IRS models |
| Specifications | 71.5 in. / 182 cm | Length for all models |
| Specifications | 47 in. / 119 cm | Width for MXR model |
| Specifications | 47.5 in. / 121 cm | Width for S/IRS models |
Featuring a modular arrangement of
Engine Components: Wiring diagrams are provided for all electrical systems, including the starter, ignition, lighting, and charging systems.
Fuel System: Fuel system procedures are documented for the Keihin FCR-MX 39mm carburetor, including jetting guidelines and exploded views.
Drivetrain: Adjustment procedures for the transmission, drive chain, and clutch are detailed.
Suspension: Front and rear suspension setup and adjustment procedures for both MXR/S and IRS models are covered.
Brakes: Brake system inspections, pad replacement, disc inspection, and fluid replacement procedures are thoroughly documented.
This manual documents torque specifications for critical fasteners to ensure proper bearing preload accuracy for safe operation.
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