Polaris 419C manual

Read this manual carefully . It contains important safety information. Adult supervision is required at all times. Operation is prohibited for anyone under age 10. OU TL A W 90 SPO R T SM AN 90 Pantone 419C Owner's Manual for Maintenance and Safety[...]

A card containi ng importan t A TV safety information should be att ached to the owner's man ual on the next page. If you ca nnot locate this card, or if it has been removed, please ca ll 1-800-342-376 4 for assistance. WA R N I N G The engine exhaust from this produ ct contains chemicals known to the S tate of California to cause cancer , bir[...]

1 V isit us at www .polaris.com[...]

2 POLARIS®, SPOR TSMAN® and OUTLA W® are registered trademarks of POLARIS Industries I nc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the d esign and quality of production components, some minor discrepa[...]

3 We lc o me Dear Parents: W e believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. W e've provided th is owner's manual to assist you and your children in learning about safe operation and care of your new A TV . A POLARIS A T V is not a toy and can be hazar dous to operate. Make sur e [...]

4 Wel c om e Dear Children: Before you ride your new POLARIS A TV , there are some important things that you need to know . Y ou must learn how to keep yourself a nd those around you safe while you're riding. Y our parents and Polaris want you to enjoy riding your new A TV , and that's why you need to read and understand the information i[...]

5 T able of Content s Introduction . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . . 8 Y outh Section . . . . . . . . . . . . . . 39 Know Y our A TV . . . . . . . . . . . 40 Pre-Ride Check . . . . . . . . . . . 47 Riding Rules . . . . . . . . . . . . . 50 Adult Section . . . . . . . . . . . . . . . 55 V ehicle I[...]

6 Introduction Safety Words and Sym bols The following signal wo rds and symbols appear throughou t this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol ind icates a potential personal injury hazard. DANGER A DANGER ind[...]

7 Introduction Failure to follow the warnings an d safe ty precautions contained in this manual can result in severe injury or death. A POLARIS A TV is not a toy and ca n be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occ ur quickly , even during routine maneu[...]

8 Safety Safety T raining A TV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the A TV to take a training course. If you purchased a new POLARIS A TV in the United S tates, your dealer provided information about the authorized A TV RiderCourse sm that is available to you and [...]

9 Safety Safety T raining If you purchased a used POLARIS A TV in the United States, you can enroll in the A TV RiderCourse sm for a fee. Call A TV Enrollment Express at (800) 887-2887 or visit www .atvsafety .org. If you purchased a POLARIS A T V outside the United S tates, please contact your dealer or local law enforcement agencies for infor- ma[...]

10 Safety Riding Gear Always wear clothing suited to the type of riding. A TV riding requires special protective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety stan- dards. Approved [...]

11 Safety Riding Gear Eye Protec tion Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equi pment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make sure prot[...]

12 Safety Equipment Modifications Y our POLARIS vehicle is designed to provide safe operation when use d as directed. W ARNING! Modifying this vehicle in any wa y can change the top speed, stability a nd handling performance of this vehicle. Modifica ti ons that increase speed, decrease stability or change performance may present a greater risk to [...]

13 Safety Safety W arnings Failure to operate the A TV prop erly can result in a collision, loss of control, a ccident or overturn, which may result in serious injury or death. Be sure to read all of the following warnings about driv ing ha zards and how to avoid them. These warnings are provided for your child's safety . Be sure to explain to[...]

14 Safety Safety W arnings Operating Without Instruction Operating this A TV without proper inst ruction increases the risk of an accident. The operato r must understand how to operate the A T V properly in different situations and on different types of terrain. Beginning and inexperienced operators should complete an A TV training course. They sho[...]

15 Safety Safety W arnings Handling Gasoline Gasoline is highl y flammable and explosive under certain conditio ns. • Never allow a child to refuel or handle gasoline. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open[...]

16 Safety Safety W arnings Failure to Inspect Be fore Operating Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Always follow all inspe ction and maintenance procedu res and sched[...]

17 Safety Safety W arnings Carrying a Passenger Carrying a passenger greatly reduces the operator's ability to balance and control the A TV , which may result in an accident or overturn. Never carry a passenger on this A TV . Using Alcohol or Drugs Operating the A TV after consuming alcohol or drugs could adverse ly affect operator judgment, r[...]

18 Safety Safety W arnings Operating on Pavement Operating an A T V on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result in loss o f control and accident o r overturn. Avoid operating the A TV on pavement. A TV tires are designed for off -road use. If it's una[...]

19 Safety Safety W arnings Operating at Excessive S peeds Operating the A TV at excessive speeds increases the operator's risk of l osing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating cond itions, and your experience. Physical Control of the A TV Removing a hand from the handlebars or [...]

20 Safety Safety W arnings T urning Improperly T urning improperly could cause l oss of traction, loss of control, accident or overturn. Always follow proper proced ures for turning as describ ed in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn a[...]

21 Safety Safety W arnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 84. Operating on Steep Hills Operating on excessively ste ep hills could cause an overturn. Never operate on hills too steep for the A [...]

22 Safety Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedure s for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while trave ling downhill. See page 87. • Always check the terrain ca[...]

23 Safety Safety W arnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn . Avoid crossi ng the side of any hill unless absolutely necessary . If crossing a hillside is unavoidabl e, always follow proper procedures as described in the owner's manual. See page 86. Never at[...]

24 Safety Safety W arnings St a lling While Climbing a Hill S t alling, rolling backw ards or imp r operl y dismounting while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost If you lose all forward speed: Kee p your weight uphill. Apply the front brakes gradually (right leve[...]

25 Safety Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng on exce ssively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough , slippery or loose terrain until you've learned and practiced the skills necessary to c[...]

26 Safety Safety W arnings Operating in Unfamiliar T errain Failure to use extra caution when operati ng on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. T ravel slowly and use extra caution when operating on unfamiliar te rrain.[...]

27 Safety Safety W arnings Improper V ehicle Modifications Improper installation of accessories or modification of the A TV may cause changes in handling, which could cause loss of control or an accident. Never modify the A TV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine POLARIS[...]

28 Safety Safety W arnings Operating Through Deep W ater Operating the A T V through deep or fast-flowing wate r could cause the tires to float, causing loss o f control or overturn. Avoid operating through deep o r fast-flowing water . If it's unavoidable to enter water that exceeds the height of the footrests: • T ravel slowly . • Balanc[...]

29 Safety Safety W arnings Improper Cargo Loading Overloading the A TV or ca rryi ng/towing cargo may cause changes in handling, which could ca use loss of contro l or an accident. Never haul cargo or tow a load with thi s A TV . Never tow or pull an object behind the A TV . A wagon, sled or other towed object does not have brakes or steering. The [...]

30 Safety Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bod ies of water may result in serious injury or death if the A TV and/or the operator fall through the ice. Never operate the A TV on a frozen body of water . Operating a Damaged A TV Operating a dama ged A TV can result in an accident. After any overturn or accide[...]

31 Safety European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration leve ls of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty of vibr[...]

32 Safety Safety Labels and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic l[...]

33 Safety Safety Labels and Locations Operation W arning W ARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gear . Never use on public roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: without proper training or instruction; at speeds too fast for your skills o[...]

34 Safety Safety Labels and Locations Discretionary W arning W ARNING Never operate this A TV on HILLS steeper than 15 degrees 15°. T o prevent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill. REVERSE operation can be dangerous even at low speeds. S teering becomes difficult. T o prevent loss of control, avoid [...]

35 Safety Safety Labels and Locations Tire Pressure W ar ning (OUTLA W 90) W ARNING Improper tire pressure or overloading can cause loss of co ntrol. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 p si (20.7 kPa) • Maximum Weight Cap acity 180 lbs. (81.7 kg) Tire Pressure W ar nin[...]

36 Safety Safety Labels and Locations No Passenger W arning W ARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJUR Y or DEA TH.[...]

37 Safety Safety Labels and Locations SPORTSMAN 90 Rack W arning W ARNING • DO NOT TOW . V ehicle damage or tipo ver may result causing severe injury or death. • Maximum Rack Loads: Front 15 lbs. (7 kg) Rear 30 lbs. (14 kg)[...]

38 Safety Safety Labels and Locations Clutch Cover W a rning W ARNING NO STEP • Moving parts hazard under belt-clutch guard. T o pre- vent serious injury , do not operate vehicle with guard removed. • Do not touch clutch cover , cover may become hot. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and ex[...]

39 Y outh Section[...]

40 Know Y our A TV PA R E N T S : POLARIS Y outh A TVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experi ence. More information on speed limiting functions can be found beginni ng on page 126. These units are not designed for adult use. Seri ous damage to the veh icle ma[...]

41 Know Y our A TV Before you have an adult start the engine for you for the first time, let's l earn about the con- trols on your new A TV . 1. Engine S top Switch - When the engine is running, push this button down to shut the engine off quickly . The button must be up before you can start the engine again. 2. Horn Button - Press the horn bu[...]

42 Know Y our A TV 4. Kick-S tart Lever - If your battery is too weak to start your A TV , you can push down on the kick-start lever with your foot to start the engine. Have an adult show you how it works. Read more about how to use the kick-start on page 68. 5. Shift Lever - The shift lever is on the right side of your A TV . Read about how to use[...]

43 Know Y our A TV 6. Gas Cap - The gas cap has to be taken off when an adult puts gas in your A TV . Never take the gas cap of f. Always make sure it's tightly closed. Always have an adult put gas in your A TV . Never try to do it yourself. 7. Seat Latch - The seat latch is under the left edge of the seat. Reach under the left rear fender and[...]

44 Know Y our A TV 8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the A TV . The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you could lose control of th e A TV and be seriou[...]

45 Know Y our A TV 9. Ignition Switch - The ignition switch key must be turned on before pushing the starter button. Y o u can also use this key to turn off the engine. 10. T ether S trap and Switch - The tether strap must always be attached snugly to your right wrist and to your A TV every time you drive. If you fall off your A TV , the tether str[...]

46 Know Y our A TV Let's review th e three ways to stop th e engine of your A TV : 1. Push the engine stop switch down. 2. Pull the tether strap off the A TV . 3. T urn the key off.[...]

47 Pre-Ride Check W e're almost ready to have an adult start your A TV . But before the A TV is started for the first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check some things on your A TV before starting it. Let's learn about these things now . 1. Make sure the throttle doe[...]

48 Pre-Ride Check 2. Make sure the brake s don't stick. Check the brake levers by squeezing them toward the handlebar and then letting go. They should come right back to where they were before you squeezed. If they go back slowly or stay close to the handlebar , your A TV has sticky brakes. They must be fixed before you can ride your A TV safe[...]

49 Pre-Ride Check 4. If you used the storage area under the seat, make sure the seat is locked in place. 5. Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been running and it can burn your skin if you touch it. Children must never check the oil on their own. An adult should always be in char ge[...]

50 Riding Rules Now you're ready to learn about riding your POLARIS A TV . There are some things you can do and there are some things you must never do . Rules are very important when you're driv- ing an A TV . Adults have riding rules, too. The rules help keep us safe when we ride. Ź The adult with you is your teacher . Always pa y atte[...]

51 Riding Rules Ź Always wear the right kind of clothing and safety gear when riding your A TV . Helmet: Y our helmet is very important for safe riding. A helmet can prevent a se vere head injury . Eye Protecti on: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you can see where you're driving. Gloves:[...]

52 Riding Rules Ź Always attach the tether strap to your right wrist and to the A TV before riding. Ź Make sure you know where you're going to drive before your A TV is started. Make sure the area is safe all around your A TV . Ź Y our A TV is made for one person. Never carry a passenger . A passenger will make the A TV harder to drive. Y o[...]

53 Riding Rules Ź Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. Ź Never ride on public trails. Ź Don't ride your A T V on roads or over rail road tracks. Y our A TV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. ?[...]

54 Respect your A TV ; respect your environment; and you will earn the respect of everyone. Enjoy riding your new POLARIS A TV![...]

55 Adult Section[...]

56 V ehicle Identification Numbers Record your A TV's identification num- bers and key number in the spaces pro- vided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be repla[...]

57 Features and Controls Main Key Switch T urn the key clockwise to the ON position before starti ng the engine. T o avoid draining the battery , always turn the key to the OFF position when the engine is not running. Always remove the ignition key when the vehicle is not in use. Key Key OUTLA W SPORTSMAN[...]

58 Features and Controls Engine Stop Switch The engine will not start or run when the stop switch is down, in the OFF position. Its pur - pose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency . Both the main switch and the engine stop switch shut off all electrical power to the entire veh[...]

59 Features and Controls Horn Button Use the horn for emer gencies and to let others know you’re near . Engine St art Button The start button is located s lightly above the choke lever . Follow the S tarting the Engine procedure beginning on page 76.[...]

60 Features and Controls Throttle Controls Operating an A T V with sticking or improperly operating throttle controls could cause an accident a nd lead to severe injury or death. Never start or operate an A TV with a sticking or improperly ope rating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or ma[...]

61 Features and Controls Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released. This A TV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable shoul[...]

62 Features and Controls Shif t Lever T o change gears, stop the A TV . With the engine idling, move the lever to the desired gear . Do not try to shift gears with engine speed above idle or while the A TV is moving. Maintaining shift linkage adjustment is important to assure proper transmis sion function. See your dealer if you experience any shif[...]

63 Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes. W ARNING! Appl ying only one brake could cause loss of cont rol and result in serious injury or death. Always apply both brakes at the same time. Rea[...]

64 Features and Controls Brakes Parking Brake 1. Squeeze the left brake lever . 2. Push the parking brake lock down to lock the brake lever in place. 3. Release the brake lever . 4. T o release the parking brake lock, squeeze and release the brake lever . The parking brake will release automatically . 5. Always lock the parking brake whenever the v[...]

65 Features and Controls Light s POLARIS Y outh A TVs are not equipped with lights that are designed for driving in the dark. Do not operate this A TV after dark. U se caution and drive at reduced speeds in conditi ons of reduced visibility . This A TV is designed for off-road use only . Do not operate this A T V on streets or highways. Indicator L[...]

66 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container . See page 168 for the part numbers of POLARIS products. Use unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. No[...]

67 Features and Controls Fuel V alve The fuel valve is located on the left side of the A TV . It has three settings. OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. The reserve setting allows operation for approximately 7-10 miles (1 1-16 km). Always refill the gas tank [...]

68 Features and Controls Kick-S t art Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Lock the parking brake. 4. Fold out the kick-start lever on the left side of the A TV . Tip [...]

69 Operation Failure to operate the A TV prop erly can result in a collision, loss of control, a ccident or overturn, which may result in serious injury or death. Read an d understand all safety wa rnings outlined in the safety section of this owner ’s manual. Break-in Period The break-in period for your new POLARIS 4-cycle A TV is defined as the[...]

70 Operation Break-in Period 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. See page 15. 2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the proper range. See page 109. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with op[...]

71 Operation Break-in Period 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 72. 6. Perform the following maintenance at the end of the break-in period. Item End of Break-In Remarks See Page Engine oil change Perform break-in oil change 1 10 Oil pre-filter screen Clean filt[...]

72 Operation Pre-Ride Inspection Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always insp ect the A TV before each use to make sure it's in safe operating condition. Pre-Ride Checklist Item Remarks Page Brake system / lever travel Ensure proper operation 129, 133[...]

73 Operation Pre-Ride Inspection Pre-Ride Checklist Item Remarks Page Throttle Check for proper operation 47, 60, 61 Engine stop switch Check for proper functio n 58 Daytime running lights (if equipped) Check for proper operation 149 Brakelight Check for proper operatio n 147 Air filter , pre-filter Inspect, clean or replace 140 Drive chain Check c[...]

74 Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 8. 2. Do not allow anyone under age 10 to operate this vehicle. 3. Never carry a passenger on this A TV . 4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Operate this vehicle o[...]

75 Operation Safe Operation Practices 7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the han- dlebars while operating, and always keep both feet on the footrests. 8. Never consume alcoho l or drugs before or wh[...]

76 Operation St arting the Engine NOTICE: Operating the A TV immediately after starting could cause eng ine damage. Allow the engin e to warm up for several minutes before operating. 1. Shift the transmission to neutral. 2. Lock the parking brake. 3. T urn the fuel valve on. 4. Sit on the vehicle. Attach the tether strap to the A TV and to your wri[...]

77 Operation St arting the Engine 7. T urn the ignition key to ON. 8. Squeeze the rear brake lever and press the starter button. The rear brake lever must be engaged or the engine won't start. 9. Do not press the throttle while starting the en gine. Activat e the starter for a maximum of five seconds, releasing the button when the engi ne star[...]

78 Operation Stopping the Engine 1. Release the throttle completely . 2. Apply the brakes until the vehicle stops moving. 3. Shift the transmission to neutral. 4. Stop the engine. There are three ways to stop the engine: • T urn the key of f. • Push the engine stop switch down. • Pull the tether strap off the A TV . 5. Lock the parking brake.[...]

79 Operation Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Shift the transmission to neutral. 3. Star t the engine and allow it to warm up. 4. Check your surroundings and determine your path of travel. 5. Squeeze the left brake lever . 6. Shift the transmission to the desired gear . 7. Slowly [...]

80 Operation Making T urns Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at al l times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly . T o turn, steer in the direction of the turn, leaning [...]

81 Operation Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly .[...]

82 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas.[...]

83 Operation Driving on Slippery Surfaces 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shif ting your body weight forward. Sideways skid T urn in direction of skid[...]

84 Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (15° maximum). 3. Always check the terrain carefully before ascending any hill. 4. [...]

85 Operation Driving Uphill 5. Keep both feet on the footrests. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the A TV to flip over backwards. 8. Never go over the top of any hill at high speed. An obst acle, a sharp drop, or another vehicle or person could be on th[...]

86 Operation Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Impro pe r procedure could cause loss of control or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper bod[...]

87 Operation Driving Downhill When driving downhill, follow these precau- tions: 1. A void steep hills (15° maximum). 2. Shift body weight uphill. T ransfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when trav- eling downhill can cause loss of control. 5. Apply the front and rear brakes at the[...]

88 Operation T urning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2. Shift the transmission to neutral. 3. Shut off the engine. 4. Dismount on the uphill side of the vehicle, or on the left i[...]

89 Operation T urning Around on a Hill 7. Lock the parking brake and remount the A TV from the uphill side, keeping body weight uphill. 8. Restart the engine. 9. Squeeze the rear brake lever . 10. Shift the transmission to forward gear . 1 1. Release the parking brake and drive slowly , controlling speed with the rear brake, until the A TV is on mo[...]

90 Operation Parking on a Hill or Incline A void parking on a hill or incline i f pos- sible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Lock the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illus- tration. 4. T urn the fuel valve of f.[...]

91 Operation Driving Over Obst acles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operat- ing in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. T ravel slowly and use extra caution when operating on unfamiliar t[...]

92 Operation Driving Through W ater Y our A TV can safely operate through shallow water . The recommended maximum depth for your A TV is below the bottom of the footrests. Follow these precautions when operating through water: 1. Determine water depth and current before entering water . 2. If crossing a stream, choose a crossing where both banks ha[...]

93 Operation Driving Through W ater 4. After driving through water , dry the brakes by applying light pressure to the levers (while moving) until braki ng action is normal. If you do not perform this procedure, your brakes may be ineffective. NOTICE: Serious engine damag e can result if the vehi cle is not thoroughly i nspected after operating in w[...]

94 Operation Hauling Cargo The SPOR TSMAN 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling car go on the follo wing pages. Never carry car go on the OUT - LA W 90. Overloading the vehicle or carryi ng cargo improperly can alter vehicle handling and may cause loss of control, which can result in se[...]

95 Operation Hauling Cargo • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section beginning on page 162. • Secure all cargo before driving. Lo ose cargo may move or shift, which could cause loss of control or a tipover . Use suitable tie-downs or rope to secure the ca rgo. Do not allow cargo or[...]

96 Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requ irements. Operation on Public Lands in the U.S.A. Y our POLARIS vehicle has a spark arrester that was tested and quali[...]

97 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related comp onents must be ma intained at POLARIS specifications to achieve opti- mal performance. Engine idle speed is the only adju stment POL[...]

98 Maintenance Periodic Maintenance Chart T o help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour . V ehicles subjected to severe use must be inspe[...]

99 Maintenan ce Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace part s as necessary . When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer . Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qu[...]

100 Maintenance Periodic Maintenance Chart W ARNING! Imp roperly performing the procedures marked with a “D” could result in component failure and cause an accident, which may result in serious inju ry or death. Always have an authorized POLARIS dealer perform these services. Maintenance Chart Key Symbol Description Ź Perform these operations [...]

101 Maintenan ce Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) D S teering -- Daily -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Check- list. 72 Front suspension -- Daily -- Rear suspension -- Daily -- Tires -- Daily -- Brake l[...]

102 Maintenance Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance In terval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) Drive chain -- Daily -- Inspect daily; adjust and[...]

103 Maintenan ce Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) Battery 20 Monthly 200 (320) Check terminals; clean; test 150 Ź Engine oil change 30 6 M 300 (480) Drain and change the oil 1 10 Ź T ransmission oil 40 12 M 400 (640) Drain and change the oil 1 14 Ź Oil pre-fi[...]

104 Maintenance Periodic Maintenance Chart Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services. Item Maintenance In terval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) E Carburetor air intake ducts/flange 50 6 M 500 ([...]

105 Maintenan ce Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) Ź Wiring 100 12 M 1000 (1600) Inspect for wear , routing, security; apply dielectric grease to connec- tors subjected to water , mud, etc. -- D Clutches (drive and driven) 100 12 M 1000 (1600) Inspect; clean; re[...]

106 Maintenance Lubrication Guide Ź Perform these procedures more often for vehicles subjected to severe use. Item Lube Method Engine Oil PS-4 Extreme Duty 10W-50 4-Cycle Oil See page 108. Gearcase (T ransmission) Oil Level AGL Gearcase Lubric ant & T ransmission Fluid See page 1 14. Drive Chain POLARIS Chain Lube or SAE 80/90 See page 137. Ź[...]

107 Maintenan ce Lubrication Guide Grease Point s Grease Points[...]

108 Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98. POLARIS re commends the use of POLARIS PS-4 Extreme Duty 4-Cycle engine oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automo[...]

109 Maintenan ce Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. W ipe it dry with a clean cloth. 3. Reinstall the dipstick completely . 4. Remove the dipstick and check the oil level. Tip : A rising oil level between checks in cool w[...]

110 Maintenance Engine Oil Change 1. Position the vehicle on a level surface. 2. Clean the area around the pre-filter plug. 3. Star t the engine. Allow it to idle for two to three minutes. 4. Stop the engine. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.[...]

111 Maintenan ce Engine Oil Change 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely . 7. W ash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry . 8. Clean the pre-filter plug. Install a new sealing washer on the plug. The sealing surfaces on the plu[...]

112 Maintenance Engine Oil Change 10. Reinstall the pre-filter drain plug. T orque to 1 1 ft. lbs. (15 Nm). 1 1. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. See the specifications section beginning on page 162 for capacities. 12. Reinstall the dipstick. 13. Star t the engine. Allow it to idle for one to two min[...]

113 Maintenan ce Fuel Filter The POLARIS A TV is equipped with an in-line fuel filter . This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. Do not attempt to clean the fuel filter .[...]

114 Maintenance T ransmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of the A TV . Maintain the oil level at the botto m of the fill plug hole threads. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98. POLARIS recommends the use of AGL[...]

115 Maintenan ce T ransmission Oil Change 1. Position the vehicle on a level surface. 2. Remove the fill plug. 3. Place a drain pan under the gearcase. 4. Remove the drain plug. Allow the oil to drain completely . 5. Clean and reinstall the drain plug. T orque to 14 ft. lbs. (19 Nm). 6. Add the recommended oil. Maintain the oil level at the bottom [...]

116 Maintenance Sp ark Plugs Refer to the specifications section beginning on page 162 for spark pl ug and gap specifica- tions. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should[...]

117 Maintenan ce Sp ark Plugs Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white. A white insulator tip indicates overheat- ing, caused by use of an[...]

118 Maintenance Cylinder Head T orque Have your dealer check the A TV cylinder head for proper torque at the first service, or after 25 hours. V ehicle Immersion If the vehicle tips or overturns in water deeper th an the footrest level, or if the engine stops during or after operating in water , restartin g WILL result in serious engine damage. T r[...]

119 Maintenan ce V ehicle Immersion 5. Loosen the carburetor drain screw . 6. T urn the engine over several times using the electric start. 7. Dry the spark plug and reinstall it, or replace it with a new plug. 8. T ighten the carburetor drain screw . 9. T urn the fuel valve on. 10. Attempt to start the engine. If necessary , repeat the drying proc[...]

120 Maintenance Const ant V ariable T ransmission (CVT) System Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will ca[...]

121 Maintenan ce CVT Drying There may be some instances wh en water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bot- tom of the CVT cover . 1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2. Shift the transmission to neutral[...]

122 Maintenance Sp ark Arrester T o remove accumulated carbon, clean the spark a rrester at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. Failure to heed these warnings could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Allow components to cool suffi[...]

123 Maintenan ce Sp ark Arrester 1. Remove the six bolts and remove the arrester from the end of the muf fler . 2. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary , blow debris from the screen with com- pressed air . 3. Inspect the screen for wear and damage. Replace the arrest[...]

124 Maintenance Carburetor Y our POLARIS A TV is calibrated at the factory for optimal performance at altitudes ranging from zero to 8,000 feet (2400 m) and temperatur es above 15° F (-9° C). Refer to the specifi- cations section beginning on page 162 for carburetor and jetting specifications. Any jetting changes must be made only by an authorize[...]

125 Maintenan ce Carburetor If engine idle speed is too high the vehicle will creep. If idle speed is t oo low the engine wi ll stall. T o adjust idle speed, do the following: 1. Lock the parking brake. 2. Star t the engine. 3. Allow the engine to warm up for approximately five minutes. 4. Adjust the carburetor idle screw either in or out until the[...]

126 Maintenance Speed Control System Per ANSI / SVIA-1-2010 (sec. 6.2) AS DELIVERED T O THE CONSUMER, the speed of youth models is restricted to 10 MPH or less for the 50cc Y -6+ models and 15 MPH or le ss for the 90cc Y -10+ models. The dealer CANNOT , under any cir cumstances, either prior to the sale or later , even at the consumer's r eque[...]

127 Maintenan ce Speed Control System Throttle Stop Speed Control System Use the following procedure to control how far the throttle opens. 1. Loosen the jam nut. 2. T urn the screw inward to reduce speed or outward to increase speed. 3. T ighten the jam nut after adjusting. Jam Nut Screw[...]

128 Maintenance Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay . It should be kept between 1/16" and 1/8" (1.5 - 3.2 mm). If adjustment is required, turn the adjustment nut until the freeplay falls in to the acceptable limit. Adjustment Nut 1/16 " - 1/8[...]

129 Maintenan ce Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals rec- ommended in the Periodic Maintenance Chart beginning on page 98. If the free- play isn’t at specification, adjust the freeplay as outlined on the following pages. Brake Freeplay Spe cifications Model Front Brake Rear Brake 90cc Models .[...]

130 Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground. 4. While rotating the left front wheel, tighten the upper front brake adjuster nut[...]

131 Maintenan ce Brake Freeplay Front Brake Adjustment 6. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 7. When you begin to feel a slight drag in wheel rotat ion, loosen the adjuster nut one full turn. 8. V erify that the right-hand brake functions correctly . 9. V erify that brake leve[...]

132 Maintenance Brake Freeplay Rear Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the rear of the vehicle by placing a suit able stand under the frame. The rear tires should be slightly off the ground. 4. While rotating the rear wheels, tighten the rear brake wing nut at the rear brake[...]

133 Maintenan ce Brake Lever T ravel Check brake lever travel at the intervals re commended in the Periodic Maintenance Chart beginning on page 98. When freeplay specif ications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine when to service the brakes. Service the brakes w[...]

134 Maintenance To e A l i g n m e n t Use the following procedure to check the toe align- ment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe in jury or death can result from improper toe alignment and adjustmen t. Do not attempt to adjust tie rod alignment. All tie ro d adjustments shoul[...]

135 Maintenan ce To e A l i g n m e n t 4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 1/16 "-1/8" (2-3 mm) more than the front measure- ment on each side of the vehicle to obtain th e recommended 1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat[...]

136 Maintenance Steering Inspection Check the steering assembly pe riodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the A TV . Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease sprin[...]

137 Maintenan ce Drive Chain Lubricate the drive chain with POLARIS chain sp ray lube or an approve d chain lube at the general lubrication interval specified in the Periodic Maintena nce Chart beginning on page 98. Lubricate more often under severe use, such as in dirty or wet conditions. See page 168 for the part numbers of POLARIS products. NOTI[...]

138 Maintenance Drive Chain Slack 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. Collapse the suspension with an adjustable (buckle type) trailer tie- down strap. Fasten the strap around the axle and rear bumper tube. 3. T ighten the st rap until a straight line can be drawn [...]

139 Maintenan ce Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. T urn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. T ighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). Hold the adjuster stud securely while tightening the nut to avoid breakin[...]

140 Maintenance Air Filter 1. Remove the seat. See page 43. 2. Release the air box cover spring clips and remove the cover . 3. Remove the foam air filter . W a sh the foam filter in warm soapy water , then rinse and let dry . If the filter is damaged, install a new foam fi lter . 4. Apply a commercially available foam filter lubricant to the foam [...]

141 Maintenan ce Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter and air box cover . Secure the clips. 7. Reinstall the seat. NOTICE: Never operate the A TV with the filter element removed. Dirt will enter the engine causin g rapid wear and seve re damage to the engine.[...]

142 Maintenance Handlebar Adjustment Improper adjustment of the handleba rs or incorrect torquing of the adjuster block tightening bo lts can cause limited steering or loo se ning of the handlebars, resulting in loss of control and possible se rious personal injury or death. Follow the adjustment proc edures exactly , or see your POLARIS dealer for[...]

143 Maintenan ce Ti re s Operating your A TV with worn tires, improperly inflat ed tires, non-standard tires or improperly i nstalled tires will affect vehicle handling and could ca use an accident resulting in serious inju ry or death. Always follow all tire maintenance proced ures as outlined in this manual and on the labels on the vehicle. Alway[...]

144 Maintenance Tire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. Stop the engine and lock the parking brake. 2. Loosen the wheel bolts slightly . 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel bolts and remove the wheel. 1/8&qu[...]

145 Maintenan ce Wheel Inst allation 1. Lock the parking brake. 2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 3. Install the wheel bolts and finger tighten them. 4. Lower the vehicle to the ground. 5. Securely tighten the bolts[...]

146 Maintenance Axle and Wheel Nut s All nuts with a cotter pin installed must be service by an authorized POLARIS dealer . Wheel Hub Tightening Front wheel bearing tightness an d spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer .[...]

147 Maintenan ce T ail Light Lamp Replacement If the brakelight doesn't work, the lamp may need to be replaced. 1. Remove the two screws securing the lens cover . Remove the lens cover . 2. Remove the lamp and replace it with a new recommended lamp. 3. T est the light for proper operation. 4. Reinstall the lens cover . Screw s Cover Lamp[...]

148 Maintenance Indicator Light Lamp Replacement 1. Remove the handlebar cover or pod to access the lamps. 2. Remove the indicator wire connections from the harness. 3. Remove the nut from the back side of the indicator lamp. 4. Remove the lamp. 5. Apply dielectric grease to the socket and install the new lamp. 6. Reverse the steps to reinstall all[...]

149 Maintenan ce Daytime Running Light s Lamp Replacement (if equipped) If the daytime running lights do not operate, replace the lamps. POLARIS recommends that you install replacement lamps obtained fro m your authorized POLARIS dealer . 1. Remove the front cab (OUTLA W only). 2. Disconnect the lights from the harness. 3. Remove the rubber cover f[...]

150 Maintenance Battery Improperly connecting or disconnecting battery cabl es can result in an explosion and cause serious injury or death. When removing the battery , always di sco nnect the negative (black) cable first. When reinstalling the battery , always connect the neg ati ve (black) cable last. The battery in your POLARIS A TV is a sealed [...]

151 Maintenan ce Battery Battery Removal 1. Disconnect the hold-down straps securing the electrical box and battery in position. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable next. 4. Lift the battery out of the A TV .[...]

152 Maintenance Battery Battery Inst alla tion and Connections Always install a fully charged battery . Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary , use a .5 amp battery charger 1. Set the battery in its hol der . 2. Coat[...]

153 Maintenan ce Battery Battery Sto rage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, an d store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Cleaning Kee[...]

154 Maintenance Cleaning W ashing the A TV The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently . 3. Dry surfaces with a chamois to prevent water spots. W a[...]

155 Maintenan ce Cleaning W ashing the A TV If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. A void directing the water stream at the following items: • Wheel bearings • Radiator • T ransmission seals •B r a k e s • Cab and [...]

156 Maintenance Polishing POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Fo llow the instructions on the container . Polishing Tip s • A void the use of automotive produ cts, some of which can scratch the finish of your vehi- cle. • Always use clean cloths and pads for c[...]

157 Maintenan ce Sto ra g e Exterior Make necessary repairs and clean the vehicle as recommended. See page 153. Battery Sto rage Remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each mo nth during storage and recharge as needed to maintain a full charg[...]

158 Maintenance Sto ra g e St abilize the Fu el POLARIS Carbon Clean is a fuel stabilizer and fuel system dryer . It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacteri al growth and pro- motes better starting after the storage period. 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel T reatment or P[...]

159 Maintenan ce Sto ra g e Engine Oil Change the oil. See page 1 10. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and air filter . Clean the air box. Drain the sedi- ment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Period ic Maintenance Chart beginning on page 98. • T ransmission Oil • En[...]

160 Maintenance Sto ra g e Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 98. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the grou[...]

161 Maintenan ce T ransporting the A TV 1. Stop the engine. Place the transmissi on in gear . Lock the parking brake. 2. Secure the fuel cap, oil cap and seat. T urn the fuel valve of f. NOTICE: Always tie the frame of the A TV to the transporting uni t securely with suitable straps or rope. The rack, bumper or handlebars do not offer enough suppor[...]

162 S pecifications OUTLA W 90 Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-S troke Lubrication Wet Sump Oil Capacity 30 oz. (900 ml) Fuel Capacity 1.7 gallons (6.4 liters) Fuel Reserve Capacity .23 gallons (.86 liters) S tarting Electric with kick-start backup Drive System Automatic CV[...]

163 S pecifications OUTLA W 90 Dry Weight 270 lbs. (122.4 kg) Length/Width/Height 61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm) Wheel Base 41.5" (105 cm) Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame Brake Light S t andard Daytime Runni ng Lights St andard Carburetor Se ttings Cutaw ay n/a Pilot [...]

164 S pecifications The carburetor jetting chart above is consistent wi th the provisions of U.S.A. fed eral regulation 40 CFR 1051.1 15(d)(3). OUTLA W 90 Carburetor Jetting *Shaded cells indicate fact ory settings. AL TITUDE Meters (Feet) AMBIENT TEMPERA TURE °F: Below -2 5 -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above +60 [...]

165 S pecifications SPORTSMAN 90 Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-S troke Lubrication Wet Sump Oil Capacity 30 oz. (900 ml) Fuel Capacity 2 gallons (7.7 liters) Fuel Reserve Capacity .22 gallons (.85 liters) S tarting Electric with kick-start backup Drive System Automatic CV[...]

166 S pecifications SPORTSMAN 90 Front T ires 19 x 7 - 8 (3 psi/20.7 kPa) Rear T ires 18 x 9.5 - 8 (3 psi/20.7 kPa) Dry Weight 289 l bs. (131 kg) Length/Width/Height 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm) Wheel Base 41.5" (105 cm) Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame Brake Light S[...]

167 S pecifications The carburetor jetting chart above is consistent wi th the provisions of U.S.A. fed eral regulation 40 CFR 1051.1 15(d)(3). SPORTSMAN 90 Carburetor Jetting *Shaded cells indicate factory settings. AL TITUDE Meters (Feet) AMBIENT TEMPERA TURE °F: Below -2 5 -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above +60[...]

168 POLARIS Product s Part Number Description Engine Lub ricant 2870791 Foggi ng Oil (12 oz. Aerosol) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l) Gearcase / T ransmission Lubricant s 2878068 AGL Full Synthe tic Gearcase Lubrican t & T ransmission Fluid (q[...]

169 POLARIS Product s Part Number Description Grease 2871322 All Season Grease (3 oz./89 ml) 2871423 All Season Grease (1 4 oz./414 ml) Miscellaneous Additives 2871326 Carbon Cle an[...]

170 T roubleshooting See your POLARIS dealer if you're unable to identify solutions using the following charts. Engine T urns Over , Fails to St art Possible Cause Solution Out of fuel T urn the fuel valve to reserve, refuel Clogged fuel valve or filter Inspect and clean or rep lace W ater is present in fue l Drain the fuel system and refuel F[...]

171 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Cause So lution Low battery voltage R ech arge battery with .5 amp char ger Loose battery connections C heck all connections and tighten Loose solenoid connections C heck all connections an d tighten Possible Cause So lution Poor quality or low octane fuel Replace with[...]

172 T roubleshooting Engine Backfires Possible Cause So lution W eak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your POLARIS dealer Incorrect ignition timing See [...]

173 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Cause So lution Fouled or defective spark plugs I nspect, clean and/or replace spark plugs W orn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections a[...]

174 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommende d fuel Clogged fuel filter Replace filter Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clea n and/o r replace s[...]

175 T roubleshooting Engine Stop s or Loses Power Possible Cause So lution Out of fuel T urn the fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater present i n fuel Replace with new fuel Overuse of choke Inspect, clea n and/or replace spark plugs Fouled or defective spark plugs I nspect, clean and/or replace s[...]

176 Wa r r a n t y LIMITED W ARRANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100-1C[...]

177 W arranty W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES This POLARIS limited warranty excludes any fail ures that are not caused by a defect in material or workmanship. THIS W ARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, [...]

178 Wa r r a n t y W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES This warranty excludes damages or failures caused by abuse, accident, fire, or any other ca use other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfa[...]

179 W arranty W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES Lubricants and Fluids 1. Mixing oil brands or using non- recommended oil may cause engine d amage. W e recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by th is warrant[...]

180 Wa r r a n t y W ARRANTY COVERAGE AND EXCLUSIONS: LIMIT A TIONS OF W ARRANTIES AND REMEDIES THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FOR TH IN THIS W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BRE[...]

181 W arranty HOW TO OBT AIN W ARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration From to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that[...]

182 Wa r r a n t y HOW TO OBT AIN W ARRANTY SERVICE If you move: If you move to another country , be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country . Y ou may be required to present documentation of your move to PO[...]

183 W arranty EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give aut[...]

184 Wa r r a n t y EXPORTED PRODUCTS NOTICE If Purchased From A Private Party: If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered [...]

185 W arranty U.S.A. EP A Emissions Limited W arranty This emissions limited warranty is in addition to the POLARIS standard limi ted warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applic able U.S. Environmental [...]

186 Wa r r a n t y U.S.A. EP A Emissions Limited W arranty This emissions limited warranty covers components whose failure increases the vehicle’ s regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the v[...]

187 W arranty U.S.A. EP A Emissions Limited W arranty The following parts are considered emission-related components for evaporative emissions: *As related to the evaporative emission cont rol sy stem. • Fuel T ank • V acuum Control Diaphragms* • Fuel Cap • Control Cables* • Fuel Line • Control Linkages* • Fuel Line Fittings • P urg[...]

188 Wa r r a n t y U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF T[...]

189 W arranty U.S.A. EP A Emissions Limited W arranty This limited warranty exclude s failures not caused by a defect in material or workmanship. Th is limited warranty does not cover damage due to accidents, abuse or imprope r handling, maintenance or use. Th is limi ted warranty also does not cover any engine that has been structural ly altered, [...]

190 Wa r r a n t y U.S.A. EP A Emissions Limited W arranty California Residents Certain POLARIS off-ro ad vehicles are available in 49-state and 50-state vers ions. Only the 50-state models are certified for sale in California. The 50-sta te models avai lable for sale in Cal i fornia ar e identified by the lett er “C” in the model name (e.g., R[...]

191 Maintenance Log Present this section of your manual to yo ur dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DA TE SERVICE INTERV AL TECHNICIAN SERVICE PERFORMED / COMMENTS 10 Hours (Break-in) 40 Hours 50 Hours 80 Hours[...]

192 Maintenance Log DA TE SERVICE INTERV AL TECHNICIAN SERVICE PERFORMED / COMMENTS 100 Hours 120 Hours 150 Hours[...]

193 Maintenance Log DA TE SERVICE INTERV AL TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

194 Maintenance Log DA TE SERVICE INTERV AL TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

195 Index A Age Restrictions . . . . . . . . . . . . . . 13 Air Filter . . . . . . . . . . . . . . . . 140-141 Axle and Wheel Nuts . . . . . . . . . 146 B Battery . . . . . . . . . . . . . . . . . 150-153 Installation / Connections . . 152 Removal . . . . . . . . . . . . . . . . 151 Storage . . . . . . . . . . . . . 153, 157 Boots . . . . . . . . .[...]

196 Index H Handlebar Adjustment . . . . . . . . . 142 Hauling Cargo . . . . . . . . . . . . . 94- 95 Helmet . . . . . . . . . . . . . . . . . . . . . . 10 Horn . . . . . . . . . . . . . . . . . . . . . . . . 59 Horn Button . . . . . . . . . . . . . . . . . . 41 I Indicator L ight . . . . . . . . . . . . . . . 148 Indicator L ights . . . . . . . . [...]

197 Index S Safety Warnings . . . . . . . . . . . 13-30 Improper Tir e Maintenance . . 26 Improper Modifications . . . . 27 Jumps and Stunts . . . . . . . . . 20 Operating a Damaged ATV . . 30 Operating on Pavement . . . . 18 Operating on Public Roads . . 18 Operating on Steep Hills . . . . 21 Operating Over Obstacles . . . 27 Operating in Deep Wat[...]

W ARNING Improper vehicle use can result in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS. AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: S without proper training or instruction S at speeds too fast for[...]