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Polaris 2009 Outlaw 450 MXR Outlaw 525 S Outlaw IRS Service Manual – PDF
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Polaris 2009 Outlaw 450 MXR Outlaw 525 S Outlaw IRS Service Manual – PDF DOWNLOAD
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Description
Polaris 2009 Outlaw 450 MXR Outlaw 525 S Outlaw IRS Service Manual – PDF DOWNLOAD
FILE DETAILS:
Polaris 2009 Outlaw 450 MXR Outlaw 525 S Outlaw IRS Service Manual – PDF DOWNLOAD
Language : English
Pages : 273
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Polaris 2009 Outlaw 450 MXR Outlaw 525 S Outlaw IRS Service Manual – PDF DOWNLOAD
9921810_Chapter_1............................................................ 1 GENERAL INFORMATION...................................................... 1 VEHICLE IDENTIFICATION............................................... 2 Model Identification............................................. 2 Engine Designation Numbers....................................... 2 VIN Identification............................................... 2 Vehicle Identification Number (VIN) Location..................... 2 Engine Serial Number Location.................................... 2 VEHICLE INFORMATION.................................................. 2 Paint Codes...................................................... 2 Replacement Keys................................................. 2 Publication Numbers.............................................. 3 Standard Torque Specifications................................... 3 SPECIFICATIONS....................................................... 4 MODEL: 2009 OUTLAW 450 “MXR”..................................... 4 MODEL: 2009 OUTLAW 525 “S”....................................... 4 MODEL: 2009 OUTLAW 525 “IRS”..................................... 4 2009 OUTLAW 450 “MXR”............................................ 5 2009 OUTLAW 525 “S”.............................................. 6 2009 OUTLAW 525 “IRS”............................................ 7 SPECIAL TOOLS........................................................ 8 “Chassis” Special Tools.......................................... 8 “KTM Engine” Special Tool Cross-Reference........................ 8 KTM Engine Special Tools......................................... 9 MISC. NUMBERS / CHARTS............................................... 10 SAE Tap / Drill Sizes............................................ 10 Metric Tap / Drill Sizes......................................... 10 Decimal Equivalents.............................................. 10 Coversion Table.................................................. 11 Glossary of Terms................................................ 12 9921810_Chapter_2............................................................ 13 MAINTENANCE.............................................................. 13 PERIODIC MAINTENANCE CHART........................................... 15 Periodic Maintenance Overview.................................... 15 Break-In Period.................................................. 15 Maintenance Chart Key............................................ 15 Pre-Ride Maintenance Interval.................................... 16 Recommended Pre-Ride Fluid Level Checks.......................... 16 10 - 60 Hour Maintenance Interval................................ 17 45 - 90 Hour Grease Lubrication Maintenance Interval............. 18 90 - 300 Hour Maintenance Interval............................... 19 Maintenance References........................................... 20 LUBRICANTS AND SERVICE PRODUCTS...................................... 21 Polaris Lubricants, Maintenance and Service Products............. 21 GENERAL VEHICLE INSPECTION AND MAINTENANCE........................... 22 Pre-Ride / Daily Inspection...................................... 22 Frame, Nuts, Bolts, and Fasteners................................ 22 FUEL SYSTEM AND AIR INTAKE........................................... 22 Fuel System...................................................... 22 Fuel Lines....................................................... 22 Vent Lines....................................................... 23 Fuel Valve....................................................... 23 Carburetor General Maintenance................................... 23 Carburetor Draining.............................................. 23 Idle Speed Adjustment............................................ 24 Throttle Inspection.............................................. 24 Throttle Cable / Electronic Throttle Control (ETC) Adjustment.... 24 Choke Operation.................................................. 25 Air Filter Service (“MXR” / “S”)................................. 25 Air Filter Service (“IRS”)....................................... 26 Air Box Drain Tube............................................... 26 ENGINE AND TRANSMISSION.............................................. 27 Engine Oil Level................................................. 27 Engine Oil and Filter Service.................................... 27 Cylinder Leakdown Test........................................... 30 Valve Clearance Adjustment....................................... 30 Exhaust Pipe / Spark Arrestor.................................... 30 Engine Mount Locations........................................... 30 LIQUID COOLING SYSTEM................................................ 31 Cooling System Overview.......................................... 31 Coolant Strength / Type.......................................... 31 Cooling System Hoses............................................. 31 Recovery Bottle / Coolant Level Inspection....................... 32 Radiator / Coolant Level Inspection.............................. 32 Cooling System Bleeding.......................................... 32 Radiator Screen Removal.......................................... 33 FINAL DRIVE.......................................................... 33 Hydraulic Clutch Lever Adjustment................................ 33 Hydraulic Clutch Oil level Inspection............................ 33 Hydraulic Clutch System Bleeding................................. 34 Reverse Lock-Out Lever Inspection and Cable Adjustment........... 35 Sprocket Inspection.............................................. 35 Drive Chain Inspection / Replacement............................. 35 Drive Chain Tension.............................................. 36 Drive Chain Adjustment (“MXR” / “S”)............................. 36 Drive Chain Adjustment (“IRS”)................................... 37 Rear Driveshaft Boot Inspection (“IRS”).......................... 37 Driveshaft Boot Pressure Equalizing (“IRS”)...................... 38 ELECTRICAL AND IGNITION SYSTEM....................................... 38 Battery Maintenance.............................................. 38 Battery Inspection / Removal..................................... 39 Battery Terminals / Bolts........................................ 39 Off Season Storage............................................... 39 Charging Procedure (“MXR” / “S”)................................. 40 Charging Procedure (“IRS”)....................................... 40 Spark Plug Removal / Inspection.................................. 40 STEERING............................................................. 41 General Steering Information..................................... 41 Controls / Handlebar............................................. 41 Steering Inspection / Tie Rod Ends and Hubs ..................... 42 Toe Alignment Inspection......................................... 42 Toe Adjustment................................................... 43 SUSPENSION (450 “MXR” / 525 “S”)..................................... 44 Front Suspension Set-Up.......................................... 44 Front Spring Preload Adjustment.................................. 44 Front Shock Compression Adjustment (“MXR”)....................... 45 Rear Suspension Set-Up........................................... 45 Rear Spring Preload Adjustment................................... 46 Rear Shock Compression Adjustment................................ 46 Rear Shock Rebound Adjustment.................................... 47 SUSPENSION (525 “IRS”)............................................... 47 Front Suspension Set-Up.......................................... 47 Front Spring Preload Adjustment.................................. 48 Rear Suspension Set-Up........................................... 48 Rear Spring Preload Adjustment................................... 49 Rear Shock Compression Adjustment................................ 49 BRAKE SYSTEM......................................................... 50 Brake System Inspection.......................................... 50 Brake Pad Inspection............................................. 50 Brake Lever Position Adjustment.................................. 50 Brake Pedal Testing / Brake Light Operation...................... 50 WHEELS AND TIRES..................................................... 51 Wheels........................................................... 51 Wheel, Hub, and Spindle Torque Table............................. 51 Wheel Removal: Front or Rear..................................... 51 Tire Pressure.................................................... 51 Tire Inspection.................................................. 51 MAINTENANCE LOG...................................................... 52 9921810_Chapter_3............................................................ 53 ENGINE................................................................... 53 ENGINE SERVICE....................................................... 54 KTM 450/525 Engine............................................... 54 GENERAL ENGINE INFORMATION........................................... 54 Special Tools.................................................... 54 Accessible Components............................................ 54 Engine Removal................................................... 54 Engine Installation Notes........................................ 58 Engine Break-In Period........................................... 59 ES45KL / ES51KL Engine Lubrication............................... 59 ENGINE COOLING SYSTEM................................................ 59 Coolant Temperature Sensor (Dual Temp Thermal Sensor)............ 59 Cooling System Flow Chart........................................ 59 Cooling System Pressure Test..................................... 60 Cooling System Specifications.................................... 60 9921810_Chapter_4............................................................ 61 FUEL SYSTEM.............................................................. 61 CARBURETOR SERVICE................................................... 62 Keihin FCR-MX 39 mm Carburetor................................... 62 GENERAL INFORMATION.................................................. 62 Jetting Guidelines............................................... 62 Carburetor Jetting............................................... 62 Keihin Optional Jet Part Numbers................................. 62 KEIHIN FCR-MX 3900 CARBURETOR........................................ 63 Exploded View.................................................... 63 FUEL TANK............................................................ 64 Exploded View.................................................... 64 Fuel Tank Removal................................................ 65 FUEL PUMP............................................................ 66 Location / Operation............................................. 66 Service / Replacement............................................ 66 9921810_Chapter_5............................................................ 67 BODY / STEERING / SUSPENSION............................................. 67 GENERAL INFORMATION.................................................. 68 Torque Specifications............................................ 68 Special Tools.................................................... 68 BODY ASSEMBLY........................................................ 69 Exploded View.................................................... 69 BODY COMPONENT REMOVAL............................................... 70 Seat............................................................. 70 Front Cover...................................................... 70 Front Cab........................................................ 70 Side Panels...................................................... 71 Rear Cab......................................................... 71 Heel Pocket...................................................... 71 STEERING ASSEMBLY EXPLODED VIEW...................................... 72 STEERING KNUCKLE..................................................... 73 Removal.......................................................... 73 Installation..................................................... 73 BALL JOINT SERVICE................................................... 73 Removal.......................................................... 73 Installation..................................................... 74 FRONT WHEEL HUB...................................................... 75 Exploded View.................................................... 75 Wheel Hub Removal................................................ 76 Wheel Hub Disassembly............................................ 77 Wheel Hub Assembly............................................... 77 Wheel Hub Installation........................................... 78 FRONT SUSPENSION EXPLODED VIEW....................................... 79 FRONT A-ARM REPLACEMENT.............................................. 80 A-arm Removal and Inspection..................................... 80 A-arm Installation............................................... 80 REAR SUSPENSION EXPLODED VIEW (“IRS”)................................ 81 REAR A-ARM REPLACEMENT (“IRS”)....................................... 82 A-arm Removal.................................................... 82 A-arm Inspection................................................. 82 A-arm Installation............................................... 83 REAR HOUSING (“IRS”)................................................. 84 Exploded View.................................................... 84 Housing Removal.................................................. 85 Housing Disassembly / Service.................................... 86 Assembly......................................................... 88 Installation..................................................... 89 REAR BEARING CARRIER (“IRS”)......................................... 90 Carrier Removal.................................................. 90 Carrier Disassembly / Inspection................................. 90 Carrier Assembly................................................. 91 Carrier Installation............................................. 92 REAR DRIVE CV JOINT (“IRS”).......................................... 93 CV Joint Removal................................................. 93 CV Joint Service................................................. 94 CV Joint Installation............................................ 95 REAR SUSPENSION SERVICE (“MXR” / “S”)................................ 96 Swing Arm Removal / Installation................................. 96 REAR AXLE SERVICE (“MXR” / “S”)...................................... 97 Removal / Disassembly............................................ 97 Installation / Assembly.......................................... 99 Axle Run-Out Inspection..........................................101 REAR AXLE HOUSING / AXLE (“MXR” / “S”)...............................102 Exploded View....................................................102 DECAL REPLACEMENT....................................................103 FRONT SHOCK EXPLODED VIEWS...........................................104 FOX™ PODIUM X ‘Piggyback’ Front Shock (450 “MXR”)................104 FOX™ PODIUM Front Shock (525 “S” / 525 “IRS”)....................105 REAR SHOCK EXPLODED VIEWS............................................106 FOX™ PODIUM X ‘Piggyback’ Rear Shock (450 “MXR” / 525 “S”).......106 FOX™ PODIUM-C Rear Shock (525 “IRS”).............................107 FOX™ PODIUM SHOCK SERVICE............................................108 General Service Information......................................108 FOX™ Front Shock Disassembly.....................................109 FOX™ Front Shock Assembly........................................112 Shock Eyelet Replacement.........................................115 FOX™ PODIUM X SHOCK SERVICE..........................................116 General Service Information......................................116 Front Shock Service Information (450 “MXR”)......................116 Rear Shock Service Information (450 “MXR” / 525 “S”).............116 FOX™ PODIUM X Shock Rebuild Information..........................117 FOX™ Podium X Shock Disassembly..................................118 FOX™ Podium X Shock Rebuild......................................120 FOX™ Podium X Shock Assembly.....................................121 FOX™ PODIUM-C SHOCK SERVICE..........................................124 General Service Information......................................124 FOX™ PODIUM-C Rebuild Information................................125 FOX™ PODIUM-C Shock Disassembly..................................126 FOX™ PODIUM-C Shock Assembly.....................................128 9921810_Chapter_6............................................................133 BRAKES...................................................................133 BRAKE SPECIFICATIONS.................................................134 General Specifications...........................................134 Torque Specifications............................................134 Special Tools....................................................134 BRAKE CALIPER EXPLODED VIEWS.........................................135 Front Brake Caliper Assembly.....................................135 Rear Brake Caliper Assembly......................................135 BRAKE SYSTEM OVERVIEW................................................136 Hydraulic System Operation.......................................136 Front Brake System - Exploded View...............................137 Rear Brake System (“MXR” / “S”) - Exploded View..................138 Rear Brake System (“IRS”) - Exploded View........................139 Service Notes....................................................140 Brake Noise Troubleshooting......................................140 Brake Fluid Replacement and Bleeding Procedure...................141 FRONT MASTER CYLINDER................................................143 Brake Lever Position Adjustment..................................143 Removal..........................................................143 Installation.....................................................144 FRONT CALIPER SERVICE................................................145 Caliper Removal and Disassembly .................................145 Caliper Inspection...............................................147 Caliper Assembly.................................................147 Caliper Installation.............................................148 FRONT BRAKE PADS.....................................................148 Pad Removal......................................................148 Pad Assembly.....................................................149 Brake Burnishing Procedure.......................................150 FRONT BRAKE DISC.....................................................150 Disc Inspection..................................................150 Disc Removal / Replacement.......................................150 REAR CALIPER SERVICE.................................................151 Caliper Removal (“MXR” / “S”)....................................151 Caliper Removal (“IRS”)..........................................152 Caliper Disassembly..............................................152 Caliper Inspection...............................................153 Caliper Reassembly...............................................153 Caliper Installation (“MXR” / “S”)...............................154 Caliper Installation (“IRS”).....................................155 REAR BRAKE PADS......................................................155 Pad Removal......................................................155 Pad Installation.................................................156 Brake Burnishing Procedure.......................................157 REAR BRAKE DISC......................................................157 Disc Inspection..................................................157 Disc Removal / Replacement (“MXR” / “S”).........................158 Disc Removal / Replacement (“IRS”)...............................158 Disc Installation................................................158 TROUBLESHOOTING......................................................159 Brakes Squeal....................................................159 Poor Brake Performance...........................................159 Lever Vibration..................................................159 Brakes Lock......................................................159 9921810_Chapter_7............................................................161 ELECTRICAL...............................................................161 GENERAL INFORMATION..................................................162 Special Tools....................................................162 Electrical Service Notes.........................................162 COMPONENT LOCATION (CHASSIS).........................................162 450 “MXR” / 525 “S”..............................................162 525 “IRS”........................................................162 LIGHTING AND CONTROLS................................................163 Transmission Switch Test.........................................163 Headlight Bulb Replacement.......................................163 Headlight Housing Replacement....................................163 Headlight Adjustment.............................................164 Headlamp Switch Test.............................................164 Taillight / Brakelight Lamp Replacement..........................164 Brake Light Switch Tests.........................................165 Clutch Switch Test...............................................165 Tether Switch Test (Accessory Option)............................165 Indicator Lamp Replacement.......................................165 Electronic Throttle Control (ETC) Switch.........................166 ETC Operation Test...............................................166 IGNITION SYSTEM......................................................167 Ignition System Troubleshooting..................................167 DC / CDI Ignition................................................167 Circuit Breakers.................................................167 Cranking Output Tests............................................168 Ignition System Breakout Diagram.................................169 Ignition System Testing..........................................170 Components of DC / CDI Ignition..................................171 COOLING SYSTEM.......................................................172 Fan Control Circuit Operation....................................172 Fan Switch Bypass Tests..........................................172 Fan Switch “Hot Light” Operation.................................173 CHARGING SYSTEM......................................................173 Current Draw - Key Off...........................................173 Charging System “Break Even” Test................................173 Alternator Tests (Charging System)...............................174 Charging System Testing Flow Chart...............................175 BATTERY TESTS........................................................176 Battery Testing..................................................176 OCV - Open Circuit Voltage Test..................................176 Load Test........................................................176 Battery Terminals / Bolts........................................176 Battery Maintenance / Inspection / Removal.......................176 Battery Charging Procedure.......................................176 STARTING SYSTEM......................................................177 Starting System Circuit..........................................177 Starter System Troubleshooting...................................178 Clutch Switch Test...............................................178 Neutral Start Diode Test ........................................178 Starter Voltage Drop Testing.....................................178 Starter Motor Removal............................................178 Starter Motor Exploded View......................................179 Starter Motor Disassembly........................................180 Brush Inspection / Replacement...................................180 Armature Testing.................................................181 Starter Reassembly...............................................181 Starter Motor Installation.......................................182 Starter One-Way Clutch Inspection................................182 Starter System Testing Flow Chart ...............................183 9921810_Chapter_8_02.........................................................185 9921810_Chapter_8_04.........................................................193 9921810_Chapter_8_05.........................................................206 9921810_Chapter_8_06.........................................................231 9921810_Chapter_8_08.........................................................249 9921810_Chapter_8_09.........................................................263 9921810_Chapter_8_10.........................................................267 9921810_Wire_Diagram.........................................................272
G.B 07/04/25
