I also have an 08 Polaris Outlaw 525s, the guy I bought it off of had wrecked the front end and put it up and it sat for 2 years, when I tore into it and got the carb off and cracked open there was a green build up and all the jets were clogged, I cleaned them out with a wire and put it all back together and replaced the spark plug, now it will idle and runs good except you have to gradually accelerate then punch it, if you punch it while it is idling it kills it, how do I fix this problem?

 

Could be that you still may have a little trash stopping up the main jet,float or needle may be sticking restricting fuel flow. Plus not a bad idea since you've just got it to check the valve clearance. .005 intake and exhaust. Valves need to be checked every 15 hrs on this race bike. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Plus here's a pdf service manual if you don't have one.Index of /ORV Manuals/Polaris/Outlaw

 

thank you, the pdf didn't have the 08 model, is it the same for the 09 525s? I cleaned out the tank, lines, and the carb extremely well, I was going to jet it but I have to drill out the air fuel mixture hole and decided not to, and had messed with the needle height, if I set it to high could it be dumping in too much fuel and bogging it down

 

09 is basically the same as the 08,mainly graphics difference. Needle height does affect mid and high range,but you can drop it back down to the factory specs or lower shown in the manual and see if it helps. If it doesn't I'd still suspect a worn needle and seat and possibly float level adjustment causing excess fuel.Possibly why you have to "feather" the throttle to get it to run past an idle.Manual covers all of this,plus the valve adjustment as mentioned.