Polaris Outlaw 525 450 TROUBLESHOOTING repair guide

1. Polaris Outlaw 525 450 Brake Noise Troubleshooting

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration). If cleaning does not reduce the occurrence of brake noise, check the backing of each pad for worn spots allowing metal to metal contact. See table below:

Brake Noise Troubleshooting
Possible Cause	Remedy
Dirt, dust, or imbedded material on pads or disc	Spray disc and pads with a non–flammable aerosol brakecleaner only! Remove pads and/or disc hub to clean imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear)Improper adjustment Insufficient lever or pedal clearance Master cylinder reservoir overfilled Master cylinder compensating port restricted Master cylinder piston not returning completely Caliper piston(s) not returning Operator error (riding the brake / park brake applied)	Adjust pad stop (front calipers)Check position of controls & switches Set to proper level Clean compensating port Inspect. Repair as necessary Clean piston(s) seal Educate operator
Loose wheel hub or bearings	Check wheel and hub for abnormal movement
Brake disc warped or excessively worn	Replace disc
Brake disc misaligned or loose	Inspect and repair as necessary
Noise is from other source (chain, axle, hub, disc or wheel)	If noise does not change when brake is applied check othersources. Inspect and repair as necessary
Wrong pad for conditions	Change to a softer or harder pad

Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
• Glazed brake pads
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
• Caliper overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Fluid overfill of the reservoir
• Stuck caliper piston

2. Polaris Outlaw 525 450  Ignition System Troubleshooting

No Spark, Weak or Intermittent Spark
• No 12 volt power or ground to CDI
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Faulty engine stop switch, ignition switch, or tether
switch
• ETC switch misadjusted or faulty
• Poor ignition coil ground (e.g. coil mount loose or
corroded)
• Faulty pulse coil (measure resistance of value of pulse
coil)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
primary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto (RH)
end – should not exceed .005”
• Faulty CDI module
• Faulty 5 Amp or 10 Amp circuit breaker

3.  Polaris Outlaw 525 450  Starter System Troubleshooting

Starter Motor Does Not Turn
• Battery discharged. Low specific gravity
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter motor
or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty kill switch
• Faulty neutral diode
• Faulty clutch switch
• Faulty starter solenoid or starter motor
• Engine problem – seized or binding (can engine be
rotated easily)?
Starter Motor Turns Over Slowly
• Battery discharged
• Excessive circuit resistance – poor connections (see
Voltage Drop Test)
• Engine problem – seized or binding (can engine be
rotated easily)?
• Faulty or worn brushes in starter motor
• Automatic compression release inoperative
Starter Motor Turns – Engine Does Not Rotate
• Faulty starter drive/one way clutch
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
• Possible engine damage