2008 Polaris ATV Outlaw 450/525 Service Manual
This is a high quality, complete, searchable and indexed Service Manual for the '08 Polaris 450 and 525 Outlaw used by Polaris Dealers and professional shops.
Models covered:
- 2008 Outlaw 450 "MRX"
- 2008 Outlaw 525 "S"
- 2008 Outlaw 525 "IRS"
Manual chapters:
CHAPTER_1
- GENERAL INFORMATION
- VEHICLE IDENTIFICATION
CHAPTER_2
- MAINTENANCE
- PERIODIC MAINTENANCE CHART
- LUBRICANTS AND SERVICE PRODUCTS
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- FUEL SYSTEM AND AIR INTAKE
- ENGINE AND TRANSMISSION
- LIQUID COOLING SYSTEM
- FINAL DRIVE
- ELECTRICAL AND IGNITION SYSTEM
- STEERING
- SUSPENSION (450 “MXR” / 525 “S”)
- SUSPENSION (525 “IRS”)
- BRAKE SYSTEM
- WHEELS AND TIRES
CHAPTER_3
- ENGINE
- ENGINE SERVICE
- GENERAL ENGINE INFORMATION
- ENGINE COOLING SYSTEM
CHAPTER_4
- FUEL SYSTEM
- CARBURETOR SERVICE
- GENERAL INFORMATION
- KEIHIN FCR-MX 3900 CARBURETOR
- FUEL TANK
CHAPTER_5
- BODY / STEERING / SUSPENSION
- GENERAL INFORMATION
- BODY ASSEMBLY
- BODY COMPONENT REMOVAL
- STEERING ASSEMBLY EXPLODED VIEW
- STEERING KNUCKLE
- BALL JOINT SERVICE
- FRONT WHEEL HUB
- FRONT SUSPENSION EXPLODED VIEW
- FRONT A-ARM REPLACEMENT
- REAR SUSPENSION EXPLODED VIEW (“IRS”)
- REAR A-ARM REPLACEMENT (“IRS”)
- REAR HOUSING (“IRS”)
- REAR BEARING CARRIER (“IRS”)
- REAR DRIVE CV JOINT (“IRS”)
- REAR SUSPENSION SERVICE (“MXR” / “S”)
- REAR AXLE SERVICE (“MXR” / “S”)
- REAR AXLE HOUSING / AXLE (“MXR” / “S”)
- DECAL REPLACEMENT
- FRONT SHOCK EXPLODED VIEWS
- REAR SHOCK EXPLODED VIEWS
- FOX™ PODIUM SHOCK SERVICE
- FOX™ PODIUM X SHOCK SERVICE
- RYDE FX™ SHOCK SERVICE
CHAPTER_6
- BRAKES
- BRAKE SPECIFICATIONS
- BRAKE CALIPER EXPLODED VIEWS
- BRAKE SYSTEM OVERVIEW
- MASTER CYLINDER
- FRONT CALIPER SERVICE
- FRONT BRAKE PADS
- FRONT BRAKE DISC
- REAR CALIPER SERVICE
- REAR BRAKE PADS
- REAR BRAKE DISC
- TROUBLESHOOTING
CHAPTER_7
- ELECTRICAL
- GENERAL INFORMATION
- COMPONENT LOCATION (CHASSIS)
- LIGHTING AND CONTROLS
- IGNITION SYSTEM
- COOLING SYSTEM
- CHARGING SYSTEM
- BATTERY TESTS
- STARTING SYSTEM
GENERAL INFORMATION
DISASSEMBLING THE ENGINE
SERVICING INDIVIDUAL COMPONENTS
ASSEMBLING THE ENGINE
FUEL SYSTEM / CARBURETION
TROUBLE SHOOTING
TECHNICAL SPECIFICATIONS
WIRING DIAGRAMS
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Rated: 5 by: Matthew Posted: Friday, January 5, 2024 at 9:55PM
This is hi-quality OEM manual. Very happy with the find!
Full list of manual chapters:
CHAPTER 1
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: 2008 OUTLAW 450 "MXR"
MODEL: 2008 OUTLAW 525 "S"
MODEL: 2008 OUTLAW 525 "IRS"
2008 OUTLAW 450 "MXR"
2008 OUTLAW 525 "S"
2008 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
CHAPTER 2
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
Camber and Caster
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
Hose / Fitting Inspection
Brake Pad Inspection
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
CHAPTER 3
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
CHAPTER 4
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
CHAPTER 5
BODY / STEERING / SUSPENSION
GENERAL INFORMATION
Torque Specifications
Special Tools
BODY ASSEMBLY
Exploded View
BODY COMPONENT REMOVAL
Seat / Side Panel
Front Cab
Tank Cover
Heel Pocket
Rear Cab
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")
RydeFX Rear Shock (525 "IRS")
FOX PODIUM SHOCK SERVICE
General Service Information
FOX Front Shock Disassembly
Reassembly
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 Reassembly
RYDE FX SHOCK SERVICE
Shock Specification Chart
Piston Orientation
RydeFX Shock Rebuild Procedure
CHAPTER 6
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
MASTER CYLINDER
Removal
Disassembly
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
CHAPTER 7
ELECTRICAL
GENERAL INFORMATION
Special Tools
Electrical Service Notes
COMPONENT LOCATION (CHASSIS)
450 "MXR" / 525 "S"
525 "IRS"
LIGHTING AND CONTROLS
Transmission Switch Test
Headlight Lamp Replacement
Headlamp Switch Test
Headlight Housing Replacement
Headlight Adjustment
Taillight / Brakelight Lamp Replacement
Brake Light Switch Tests
Clutch Switch Test
Indicator Lamp Replacement
Tether Switch Test (Accessory Option)
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
Chapter 8-02
Chapter 8-04
Chapter 8-05
Chapter 8-06
Chapter 8-08
Chapter 8-09
Chapter 8-10
WIRE_DIAGRAMS
