Polaris Outlaw 450-525 ATV Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Outlaw 450-525 ATV has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL: 2009 OUTLAW 450 “MXR”
MODEL NUMBER: A09GJ45AA
ENGINE MODEL: ES045KLE013

MODEL: 2009 OUTLAW 525 “S”
MODEL NUMBER: A09GJ52AA
ENGINE MODEL: ES051KLE016

MODEL: 2009 OUTLAW 525 “IRS”
MODEL NUMBER: A09GP52AA
ENGINE MODEL: ES051KLE015

TABLE OF CONTENTS :

Chapter_1-GENERAL INFORMATION
Chapter_2-MAINTENANCE
Chapter_3-ENGINE
Chapter_4-FUEL SYSTEM
Chapter_5-BODY / STEERING / SUSPENSION
Chapter_6-BRAKES
Chapter_7-ELECTRICAL
Chapter_8_02-GENERAL INFORMATION
Chapter_8_04-DISASSEMBLING THE ENGINE
Chapter_8_05-SERVICING INDIVIDUAL COMPONENTS
Chapter_8_06-ASSEMBLING THE ENGINE
Chapter_8_08-FUEL SYSTEM / CARBURETION
Chapter_8_09-TROUBLE SHOOTING
Chapter_8_10-TECHNICAL SPECIFICATIONS
WIRE DIAGRAM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921810
Total Pages : 273

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

9921810_Chapter_1-GENERAL INFORMATION
GENERAL INFORMATION
VEHICLE IDENTIFICATION
Model Identification
Engine Designation Numbers
VIN Identification
Vehicle Identification Number (VIN) Location
Engine Serial Number Location
VEHICLE INFORMATION
Paint Codes
Replacement Keys
Publication Numbers
Standard Torque Specifications
SPECIFICATIONS
MODEL: 2009 OUTLAW 450 “MXR”
MODEL: 2009 OUTLAW 525 “S”
MODEL: 2009 OUTLAW 525 “IRS”
2009 OUTLAW 450 “MXR”
2009 OUTLAW 525 “S”
2009 OUTLAW 525 “IRS”
SPECIAL TOOLS
“Chassis” Special Tools
“KTM Engine” Special Tool Cross-Reference
KTM Engine Special Tools
MISC. NUMBERS / CHARTS
SAE Tap / Drill Sizes
Metric Tap / Drill Sizes
Decimal Equivalents
Coversion Table
Glossary of Terms
9921810_Chapter_2-MAINTENANCE
MAINTENANCE
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Break-In Period
Maintenance Chart Key
Pre-Ride Maintenance Interval
Recommended Pre-Ride Fluid Level Checks
10 – 60 Hour Maintenance Interval
45 – 90 Hour Grease Lubrication Maintenance Interval
90 – 300 Hour Maintenance Interval
Maintenance References
LUBRICANTS AND SERVICE PRODUCTS
Polaris Lubricants, Maintenance and Service Products
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Frame, Nuts, Bolts, and Fasteners
FUEL SYSTEM AND AIR INTAKE
Fuel System
Fuel Lines
Vent Lines
Fuel Valve
Carburetor General Maintenance
Carburetor Draining
Idle Speed Adjustment
Throttle Inspection
Throttle Cable / Electronic Throttle Control (ETC) Adjustment
Choke Operation
Air Filter Service (“MXR” / “S”)
Air Filter Service (“IRS”)
Air Box Drain Tube
ENGINE AND TRANSMISSION
Engine Oil Level
Engine Oil and Filter Service
Cylinder Leakdown Test
Valve Clearance Adjustment
Exhaust Pipe / Spark Arrestor
Engine Mount Locations
LIQUID COOLING SYSTEM
Cooling System Overview
Coolant Strength / Type
Cooling System Hoses
Recovery Bottle / Coolant Level Inspection
Radiator / Coolant Level Inspection
Cooling System Bleeding
Radiator Screen Removal
FINAL DRIVE
Hydraulic Clutch Lever Adjustment
Hydraulic Clutch Oil level Inspection
Hydraulic Clutch System Bleeding
Reverse Lock-Out Lever Inspection and Cable Adjustment
Sprocket Inspection
Drive Chain Inspection / Replacement
Drive Chain Tension
Drive Chain Adjustment (“MXR” / “S”)
Drive Chain Adjustment (“IRS”)
Rear Driveshaft Boot Inspection (“IRS”)
Driveshaft Boot Pressure Equalizing (“IRS”)
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance
Battery Inspection / Removal
Battery Terminals / Bolts
Off Season Storage
Charging Procedure (“MXR” / “S”)
Charging Procedure (“IRS”)
Spark Plug Removal / Inspection
STEERING
General Steering Information
Controls / Handlebar
Steering Inspection / Tie Rod Ends and Hubs
Toe Alignment Inspection
Toe Adjustment
SUSPENSION (450 “MXR” / 525 “S”)
Front Suspension Set-Up
Front Spring Preload Adjustment
Front Shock Compression Adjustment (“MXR”)
Rear Suspension Set-Up
Rear Spring Preload Adjustment
Rear Shock Compression Adjustment
Rear Shock Rebound Adjustment
SUSPENSION (525 “IRS”)
Front Suspension Set-Up
Front Spring Preload Adjustment
Rear Suspension Set-Up
Rear Spring Preload Adjustment
Rear Shock Compression Adjustment
BRAKE SYSTEM
Brake System Inspection
Brake Pad Inspection
Brake Lever Position Adjustment
Brake Pedal Testing / Brake Light Operation
WHEELS AND TIRES
Wheels
Wheel, Hub, and Spindle Torque Table
Wheel Removal: Front or Rear
Tire Pressure
Tire Inspection
MAINTENANCE LOG
9921810_Chapter_3-ENGINE
ENGINE
ENGINE SERVICE
KTM 450/525 Engine
GENERAL ENGINE INFORMATION
Special Tools
Accessible Components
Engine Removal
Engine Installation Notes
Engine Break-In Period
ES45KL / ES51KL Engine Lubrication
ENGINE COOLING SYSTEM
Coolant Temperature Sensor (Dual Temp Thermal Sensor)
Cooling System Flow Chart
Cooling System Pressure Test
Cooling System Specifications
9921810_Chapter_4-FUEL SYSTEM
FUEL SYSTEM
CARBURETOR SERVICE
Keihin FCR-MX 39 mm Carburetor
GENERAL INFORMATION
Jetting Guidelines
Carburetor Jetting
Keihin Optional Jet Part Numbers
KEIHIN FCR-MX 3900 CARBURETOR
Exploded View
FUEL TANK
Exploded View
Fuel Tank Removal
FUEL PUMP
Location / Operation
Service / Replacement
9921810_Chapter_5-BODY / STEERING / SUSPENSION
BODY / STEERING / SUSPENSION
GENERAL INFORMATION
Torque Specifications
Special Tools
BODY ASSEMBLY
Exploded View
BODY COMPONENT REMOVAL
Seat
Front Cover
Front Cab
Side Panels
Rear Cab
Heel Pocket
STEERING ASSEMBLY EXPLODED VIEW
STEERING KNUCKLE
Removal
Installation
BALL JOINT SERVICE
Removal
Installation
FRONT WHEEL HUB
Exploded View
Wheel Hub Removal
Wheel Hub Disassembly
Wheel Hub Assembly
Wheel Hub Installation
FRONT SUSPENSION EXPLODED VIEW
FRONT A-ARM REPLACEMENT
A-arm Removal and Inspection
A-arm Installation
REAR SUSPENSION EXPLODED VIEW (“IRS”)
REAR A-ARM REPLACEMENT (“IRS”)
A-arm Removal
A-arm Inspection
A-arm Installation
REAR HOUSING (“IRS”)
Exploded View
Housing Removal
Housing Disassembly / Service
Assembly
Installation
REAR BEARING CARRIER (“IRS”)
Carrier Removal
Carrier Disassembly / Inspection
Carrier Assembly
Carrier Installation
REAR DRIVE CV JOINT (“IRS”)
CV Joint Removal
CV Joint Service
CV Joint Installation
REAR SUSPENSION SERVICE (“MXR” / “S”)
Swing Arm Removal / Installation
REAR AXLE SERVICE (“MXR” / “S”)
Removal / Disassembly
Installation / Assembly
Axle Run-Out Inspection
REAR AXLE HOUSING / AXLE (“MXR” / “S”)
Exploded View
DECAL REPLACEMENT
FRONT SHOCK EXPLODED VIEWS
FOX™ PODIUM X ‘Piggyback’ Front Shock (450 “MXR”)
FOX™ PODIUM Front Shock (525 “S” / 525 “IRS”)
REAR SHOCK EXPLODED VIEWS
FOX™ PODIUM X ‘Piggyback’ Rear Shock (450 “MXR” / 525 “S”)
FOX™ PODIUM-C Rear Shock (525 “IRS”)
FOX™ PODIUM SHOCK SERVICE
General Service Information
FOX™ Front Shock Disassembly
FOX™ Front Shock Assembly
Shock Eyelet Replacement
FOX™ PODIUM X SHOCK SERVICE
General Service Information
Front Shock Service Information (450 “MXR”)
Rear Shock Service Information (450 “MXR” / 525 “S”)
FOX™ PODIUM X Shock Rebuild Information
FOX™ Podium X Shock Disassembly
FOX™ Podium X Shock Rebuild
FOX™ Podium X Shock Assembly
FOX™ PODIUM-C SHOCK SERVICE
General Service Information
FOX™ PODIUM-C Rebuild Information
FOX™ PODIUM-C Shock Disassembly
FOX™ PODIUM-C Shock Assembly
9921810_Chapter_6-BRAKES
BRAKES
BRAKE SPECIFICATIONS
General Specifications
Torque Specifications
Special Tools
BRAKE CALIPER EXPLODED VIEWS
Front Brake Caliper Assembly
Rear Brake Caliper Assembly
BRAKE SYSTEM OVERVIEW
Hydraulic System Operation
Front Brake System – Exploded View
Rear Brake System (“MXR” / “S”) – Exploded View
Rear Brake System (“IRS”) – Exploded View
Service Notes
Brake Noise Troubleshooting
Brake Fluid Replacement and Bleeding Procedure
FRONT MASTER CYLINDER
Brake Lever Position Adjustment
Removal
Installation
FRONT CALIPER SERVICE
Caliper Removal and Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
FRONT BRAKE PADS
Pad Removal
Pad Assembly
Brake Burnishing Procedure
FRONT BRAKE DISC
Disc Inspection
Disc Removal / Replacement
REAR CALIPER SERVICE
Caliper Removal (“MXR” / “S”)
Caliper Removal (“IRS”)
Caliper Disassembly
Caliper Inspection
Caliper Reassembly
Caliper Installation (“MXR” / “S”)
Caliper Installation (“IRS”)
REAR BRAKE PADS
Pad Removal
Pad Installation
Brake Burnishing Procedure
REAR BRAKE DISC
Disc Inspection
Disc Removal / Replacement (“MXR” / “S”)
Disc Removal / Replacement (“IRS”)
Disc Installation
TROUBLESHOOTING
Brakes Squeal
Poor Brake Performance
Lever Vibration
Brakes Lock
9921810_Chapter_7-ELECTRICAL
ELECTRICAL
GENERAL INFORMATION
Special Tools
Electrical Service Notes
COMPONENT LOCATION (CHASSIS)
450 “MXR” / 525 “S”
525 “IRS”
LIGHTING AND CONTROLS
Transmission Switch Test
Headlight Bulb Replacement
Headlight Housing Replacement
Headlight Adjustment
Headlamp Switch Test
Taillight / Brakelight Lamp Replacement
Brake Light Switch Tests
Clutch Switch Test
Tether Switch Test (Accessory Option)
Indicator Lamp Replacement
Electronic Throttle Control (ETC) Switch
ETC Operation Test
IGNITION SYSTEM
Ignition System Troubleshooting
DC / CDI Ignition
Circuit Breakers
Cranking Output Tests
Ignition System Breakout Diagram
Ignition System Testing
Components of DC / CDI Ignition
COOLING SYSTEM
Fan Control Circuit Operation
Fan Switch Bypass Tests
Fan Switch “Hot Light” Operation
CHARGING SYSTEM
Current Draw – Key Off
Charging System “Break Even” Test
Alternator Tests (Charging System)
Charging System Testing Flow Chart
BATTERY TESTS
Battery Testing
OCV – Open Circuit Voltage Test
Load Test
Battery Terminals / Bolts
Battery Maintenance / Inspection / Removal
Battery Charging Procedure
STARTING SYSTEM
Starting System Circuit
Starter System Troubleshooting
Clutch Switch Test
Neutral Start Diode Test
Starter Voltage Drop Testing
Starter Motor Removal
Starter Motor Exploded View
Starter Motor Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Reassembly
Starter Motor Installation
Starter One-Way Clutch Inspection
Starter System Testing Flow Chart
9921810_Chapter_8_02-GENERAL INFORMATION
9921810_Chapter_8_04-DISASSEMBLING THE ENGINE
9921810_Chapter_8_05-SERVICING INDIVIDUAL COMPONENTS
9921810_Chapter_8_06-ASSEMBLING THE ENGINE
9921810_Chapter_8_08-FUEL SYSTEM / CARBURETION
9921810_Chapter_8_09-TROUBLE SHOOTING
9921810_Chapter_8_10-TECHNICAL SPECIFICATIONS
9921810_WIRE DIAGRAM

 

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Polaris Outlaw 450-525 ATV Repair Service Manual 2009.pdf

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