Outlaw 525 S IRS / Polaris Industries Inc.
Production/model years: 2007-2008
2007-2008 Polaris Outlaw 525 S IRS ATV service manual
Models covered in this manual:
File specifications
File type: PDF
Language: English
Printable: Yes
Estimated download time: 0.38 Minutes
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Product Information
Table of Contents
General Information
-
Vehicle Identification
- Model Identification
- Engine Serial Number
- VIN (Vehicle Identification Number) Location
-
Vehicle Information
- Manufacturer’s Certification
- Replacement Keys
- Standard Torque Specifications
-
Specifications
- General Specifications
- Outlaw 500/525 Specifications
-
Special Tools
- Common Service Tools
- Special Tools List
- Manufacturer’s Tool Cross-Reference
-
Miscellaneous Information
- Maintenance Schedule
- Fluid Capacities
- Glossary of Terms
Periodic Maintenance
-
Maintenance Schedule
- Recommended Service Intervals
- Maintenance Checklist
-
Engine Oil and Filter
- Oil Change Procedure
- Oil Filter Replacement
-
Coolant System
- Coolant Replacement
- Radiator and Hose Inspection
-
Transmission and Final Drive
- Transmission Oil Change
- Final Drive Inspection
-
Fuel System
- Fuel Filter Replacement
- Carburetor Adjustment
-
Brake System
- Brake Pad Inspection
- Brake Fluid Replacement
Engine
-
Engine Removal and Installation
- Preparation for Engine Removal
- Engine Installation Procedure
-
Cylinder Head and Valve
- Cylinder Head Removal
- Valve Clearance Adjustment
-
Piston and Cylinder
- Piston Removal and Inspection
- Cylinder Boring and Honing
-
Crankshaft and Crankcase
- Crankshaft Removal
- Crankcase Inspection and Reassembly
Fuel System
-
Carburetor
- Carburetor Disassembly
- Carburetor Cleaning and Reassembly
-
Fuel Pump
- Fuel Pump Testing and Replacement
- Fuel Line Inspection
-
Air Intake System
- Air Filter Cleaning and Replacement
- Air Box Inspection
Electrical System
-
Battery and Charging System
- Battery Maintenance
- Charging System Testing
-
Ignition System
- Spark Plug Inspection and Replacement
- Ignition Coil Testing
-
Lighting and Switches
- Headlight and Taillight Maintenance
- Switches and Controls Inspection
-
Wiring Diagrams
- Complete Electrical Schematic
- Component-Specific Diagrams
Cooling System
-
Radiator and Hoses
- Radiator Inspection and Cleaning
- Hose Replacement
-
Water Pump
- Water Pump Testing
- Water Pump Replacement
-
Thermostat
- Thermostat Testing and Replacement
- Coolant Temperature Sensor Inspection
Chassis
-
Frame and Body Panels
- Frame Inspection and Repair
- Body Panel Removal and Installation
-
Suspension
- Front Suspension Adjustment
- Rear Suspension Maintenance
-
Steering
- Steering Alignment
- Steering Component Inspection
-
Wheels and Tires
- Wheel Removal and Installation
- Tire Inspection and Replacement
Drive System
-
Drive Chain and Sprockets
- Chain Inspection and Lubrication
- Sprocket Replacement
-
Differential and Axles
- Differential Fluid Replacement
- Axle Inspection and Maintenance
Braking System
-
Front and Rear Brakes
- Brake Pad Replacement
- Brake System Bleeding
-
Master Cylinder
- Master Cylinder Inspection
- Master Cylinder Rebuild
Appendix
-
Troubleshooting Guide
- Common Problems and Solutions
- Diagnostic Flowcharts
-
Technical Data
- Detailed Specifications
- Component Specifications
-
Index
- Alphabetical Index of Topics
- Quick Reference Guide
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