2009 Polaris Outlaw 450/525 Service Manual, Page 59Get this manual
ENGINE Engine Break-In Period
No single action on your part is as important as proper breakin periodCareful treatment of new engine and transmission will result in more efficient performance and longer life for bothPerform the following procedures carefullyThe break-in period for the KTM engine is defined as the first three hours of operation, or the time it takes to use 5-6 gallons (20 liters) of fuelDo not allow engine speed to exceed 7000 RPM during the break-in periodFollow the break-in period with an additional 12 hours of cautious operation, with engine speed below 75 of capacityNew and rebuilt engines require break-in oil change after hours of engine operationOIL RECOMMENDATION Polaris PS-4 Plus 2W-50 synthetic oil is specially formulated for the KTM wet-clutch transmissionNever substitute or mix oil brandsSerious engine damage can result1234567Fill fuel tank with unleaded fuel which has minimum pump octane number of 91= (R+ M)2Check oil level as indicated through the sight glassAdd oil if necessaryDrive slowly at first to gradually bring engine up to operating temperatureVary throttle positionsDo not operate at sustained idle or sustained high speedPerform regular checks on fluid levels, controls and all important areas on the vehiclePull only light loads during initial break inChange break-in oil and filters after hours of operationRemote Thermostat Bypass Cylinder Torque to: 18 ftlbs(25 Nm)