2008 Polaris Outlaw 525 IRS Owner's Manual

Repair guide for all Outlaw 525 IRS configurations, including detailed procedures for engine, drivetrain, and suspension systems. P/N 9920972 Rev 01.

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Document Details

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Document Number / Seller:
31990 / Ashley Williams
File Size:
8.81 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
ATV
Last updated / verified
Aug 19, 2025

Models Covered & Key Technical Specifications

Consolidated Repair Installation Manual: Polaris Outlaw 525 IRS (2008) Knowledge-Base

2008 Polaris Outlaw 525 IRS Owner's Manual | P/N 9920972 Rev 01. Published Electrical Specs: 12.8 volts establishes the minimum battery voltage for operation. Measured Amperage Specs: 200 w @ 3000 RPM indicates the alternator output capability. Approved Heat Dissipation: Not specified; consult dealer for details. Reference Footprint Data: 51 in. wheelbase provides stability for diverse terrain. Fundamental Securement Values: 30-35 ft. lbs. for wheel nut torques ensures secure attachment. Universal Dimensional Tolerance: 1/16" to 1/8" freeplay for throttle lever ensures responsive control.

Professional Workshop Service Manual & Technical Specifications

Consolidated Repair Installation Manual: Polaris Outlaw 525 IRS (2008) Knowledge-Base

Year-Coverage: 2008 // Reference-Category: ATV / Sport Logic // Year-Coverage: 2008

Identifier Baseline Calibration-Standards
Engine Oil Capacity 1.7 qts./1.6 l 1.7 qts. (1.6 l)
Coolant Capacity 2.25 qts./2.1 l 2.25 qts. (2.1 l)
Max. Weight Capacity 215 lbs./97.5 kg 215 lbs. (97.5 kg)
Ground Clearance 11.5 in./29 cm 11.5 in. (29 cm)
Min. Turning Radius 67 in./170 cm 67 in. (170 cm)

Maintenance information covers pre-ride inspections, fluid level checks, and component maintenance procedures for your Polaris Outlaw 525 IRS. Careful attention is given to safe operation and recommended service intervals.

Pre-Ride Inspections

The pre-ride inspection section details critical checks for brake systems, tire pressure, and fluid levels to ensure safe operation.

Fluid Levels and Maintenance

This section guides you through checking and maintaining essential fluid levels, including engine oil, coolant, brake fluid, and clutch fluid, along with their recommended service intervals.

Operation and Safety Guidelines

Essential operating procedures and safety warnings are provided for various riding conditions, including hills, slippery surfaces, and water crossings.

Specifications and Jetting Charts

Detailed specifications for the Outlaw 525 IRS, including dimensions, weight capacity, and carburetor jetting information for different altitudes and temperatures, are included.

This manual documents torque specifications for wheel nuts to ensure proper oscillation integrity.

FAQ

What is the **required** fluid capacity for the engine oil? keyboard_arrow_down

1.7 quarts (1.6 liters) is the specified engine oil capacity for the Polaris Outlaw 525 IRS.

Calculate the **specified** tire pressure for this model. keyboard_arrow_down

4 psi (27.6 KPa) is the specified tire pressure for all tires on the Outlaw 525 IRS.

What values are **essential** for throttle lever freeplay adjustments? keyboard_arrow_down

1/16" to 1/8" (1.5 - 3 mm) is the essential range for throttle lever freeplay to ensure responsive control.

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Reviews (5)

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I had a smooth download experience, and the customer support was incredibly helpful when I had questions. The manual itself is comprehensive and very useful!
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This manual is a must-have for anyone serious about their Polaris Outlaw 525 IRS! The maintenance tips are clear and easy to follow. Highly recommend!
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The troubleshooting section saved me during my last ride! Plus, the download link came quickly via email. Great service!
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This manual covers everything you need to know about the Polaris Outlaw 525 IRS. I appreciated the quick response from support when I needed assistance!
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Rated 5 out of 5 stars