Polaris Outlaw 450-525 ATV Repair Service Manual 2008

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This workshop repair service manual PDF download for the 2008 Polaris Outlaw 450-525 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: 2008 OUTLAW 450 “MXR”
MODEL NUMBER: A08GJ45AA
ENGINE MODEL: ES045KLE012

MODEL: 2008 OUTLAW 525 “S”
MODEL NUMBER: A08GJ52AA, AB
ENGINE MODEL: ES051KLE012

MODEL: 2008 OUTLAW 525 “IRS”
MODEL NUMBER: A08GP52AA
ENGINE MODEL: ES051KLE013


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
Chapter_8-04
Chapter_8-05
Chapter_8-06
Chapter_8-08
Chapter_8-09
Chapter_8-10
WIRE_DIAGRAMS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 271


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.

More Info : http://www.sitelux.com

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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: 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
    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
        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
    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
    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
    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
    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

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