Polaris Sportsman 9921796 manual

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A card containing importan t A TV safety information sh ould be attached to the owner's manual on the next page . If you cannot locate this card, or if it has been removed, plea se call 1-800-34 2-3764 for assistance. W ARNING The engine exhaust from this product contains chemicals known to the State of Ca lifornia to cause cancer , birth defe[...]

1 Visit us at www .polarisindustries.com[...]

2 POLARIS and POLARIS THE W A Y OUT are register ed tra demarks of Pola ris Industries Inc. Copyright 2008 Polaris Sales Inc. All in formation contained within this publication is based on the latest product information at the time of publicat ion. Due to constant improvements in the design an d quality of production components, some minor discrepa[...]

3 We l c o m e Dear Parents: W e believe your children should hav e the opportunity to enjoy The W ay Out experience along with you. W e've provided this owner's ma nual to assist you and your children in learn - ing about safe o peration and care of your new A TV . A Polaris A TV is not a toy and can be hazar d ou s to operate. Make sur [...]

4 We l c o m e Dear Childr en: Before you ride your new Pola ris A T V , there are some important things that you need to know . Y ou must learn how to keep yourself and th ose around you safe while you're riding. Y our parents and Polaris want you to enjoy riding you r new A TV , and that's why you need to read and understand the informa[...]

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 W ords and Symbols The following signal words and symbo ls appear throughou t this manual an d on your v ehicle. Y our safety is involved when these words and symbols are us ed. Become familiar with their meanings before r eading the manual. The safety ale rt symbol indicates a potentia l personal injury hazard. W ARNING A W A[...]

7 Introduction Failure to follow the warning s and safety precautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy an d can be hazardous to opera te. This vehicle handles differently than other vehicles, su ch as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneu[...]

8 Safety Safety T raining A TV safety training is a top priority for Polaris. When you purchased your new A TV , your dealer instructed you on the authorized A TV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and your age eli gible fam[...]

9 Safety Safety T raining If you purchased a used Polaris A TV , you can take the A TV RiderCourse sm by calling A TV Enrollment Express at (800) 887-2887 or by visiting www .atvsafety .org. Purchas- ers of a used Polaris A TV will be char ged for this training. FOR MORE IN FORMA TION ABOU T A TV SAFETY , call the Consumer Product Safety Commission[...]

10 Safety Riding Gear Always wear clothing suited to the t ype of riding. A TV riding requires special prot ective clothing for comfort and to reduce the chance of injury . Helmet W earing a helmet can prev ent a severe head injury . Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved[...]

11 Safety Riding Gear Eye Prot ection Do not depend on eyeglasses or sunglasses fo r eye protection. Whe never riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protec tive Equipment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su re p[...]

12 Safety Equipment Modifications W e are concerned for the safety of our custom ers and for the general public. Therefore, we strongly recommend that co nsumers do not inst all on a Polaris A TV any equipment that may increase the spe ed or power of the ve hicle, or make any other modifications to the vehicle for these purposes. Any modifications [...]

13 Safety Safety W arnings Failure to operate the A TV properly can result in a co llision, loss of control, a ccide nt or overturn, which may result in serious injury o r death. Be sure to read all of the following warni ngs about driving haza rds and how to avoid them. These warnings are provided for your child's safe ty . Be sure to explain[...]

14 Safety Safety W arnings Operating Wit hout Instructio n Operating this A TV without proper in struction increases the ri sk of an accident. The opera tor must unde rstand how to operate the A TV properly in different situations and on different types of terrain. Beginning and inexperie nced oper ators shoul d complete the A TV RiderCourse sm off[...]

15 Safety Safety W arnings Handling G asoline Gasoline is h ighly flammable and explosive under certain condi tions. • 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 ope[...]

16 Safety Safety W arnings Failure to Inspect Before Oper ating Failure to inspect and verify that the A TV is in safe operating conditi on before operating increases the risk of an accident. Always inspect the A T V before ea ch use to make sure it's in safe operating condition. Always fo llow all inspecti on and maintenance procedures and sc[...]

17 Safety Safety W arnings Carrying a Passenger Carrying a passenger greatly reduces the operator's abil ity to bal ance and control the A TV , which may result in an accident or overturn. Never carry a passenger on thi s A TV . Using Alcohol or Drugs Operating the A TV after consuming a lcohol or drugs could adve rsely affect operator j udgme[...]

18 Safety Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (includin g sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result i n loss of control and accident o r overturn. Avoid operating the A TV on p avement. A TV tires are desig ned for of f-road use . If it's [...]

19 Safety Safety W arnings Operating at Excessiv e Sp eeds Operating the A TV at excessive speeds increases the operator's risk of losing contro l. Always operate at a speed that' s appropriate for the terrain, the visibility and operati ng conditions, and your expe rience. Physical Control of the A TV Removing a hand from the hand lebars[...]

20 Safety Safety W arnings T urning Improperly T urning improperly could cause l oss of tracti on, loss of control, accid ent or overturn. Alw ays follow proper procedures for turning as describ ed in the owner's manual. Never turn abruptly or at sharp ang les. Never turn at high speeds. Practice tu rning at slow speeds before attempting to tu[...]

21 Safety Safety W arnings Improper Hill Clim bing Improper hill climbing c ould cause loss of control or overturn. Always follow prop er procedures for climbing hills a s described in the owner' s manual. See page 84. Operating on S teep Hills Operating on excessivel y steep hill s could cause an overturn. Never operate on hil ls too steep fo[...]

22 Safety Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper pro cedures for traveling down hills as descri bed in the owner' s manual. NOTE: A special technique is required when braking whil e traveling downhill. See page 87. • Always check the terra in[...]

23 Safety Safety W arnings Crossing Hillsides Driving on a sidehill is not recommended . Improper procedure could cause loss of control or overtu rn. Avoid crossing the side of any hill unless absolutel y necessary . If crossing a hillside is unavoid able, always follow proper procedures as described i n the owner's man ual. See page 86. Never[...]

24 Safety Safety W arnings S t alling While Climbing a Hill S talling, rolling backw ards or improperly dismo unting 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 : Keep yo ur weight uphill . Apply the front brakes gradually (right lever[...]

25 Safety Safety W arnings Operating on Slippery T errain Failure to use extra caution when ope rating on excessively rough, slippery or loose terrain could cause loss of tracti on, loss of control, accid ent or overturn. Do not operate on excessive ly rough, slippery o r loose terrain until you've learned and practiced the skills ne cessary t[...]

26 Safety Safety W arnings Operating in Unfamiliar T errain Failure to use extra caution when ope rating on unfamiliar terrain coul d 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 unfamil iar terrain[...]

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 co uld caus e loss of control or a n accident. Never modify the A TV through impro per installation or use of accessories. All part s and accessories added to the vehicle mu st be genuine P[...]

28 Safety Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating throu gh deep or fa st-flowing wate r . If it's unavoidab le to enter water that exceeds the height of the footre sts: • T ravel slowly . • Balan[...]

29 Safety Safety W arnings Improper Cargo Loading Overloading the A TV or carrying/towing carg o may cause changes in handling, which c oul d cause loss of control or an accident. Never haul cargo or tow a load with this A TV . Never tow or pull an object behind th e A TV . A wagon, sled or other towed object does not have brakes or steering. The o[...]

30 Safety Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodies of water ma y result in serious injury or death if the A TV and/or the operator fall through the ice. Never opera te the A TV on a frozen body of water . Operating a Damaged A TV Operating a da maged A TV can result in an accident. After any overturn or accid[...]

31 Safety Safety W arnings Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass. Always in[...]

32 Safety Safety Labels and Locations W arning labe ls have been placed on the vehi cle for your protection. Read and follow the instructions on each label caref ully . If any of th e labels shown in this manual differ from the labels on your vehic le, always read and follo w the instructions of the labels on the vehicle. If an informational or gra[...]

33 Safety Safety Labels and Locations Operation W a rning W ARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved he lmet and protective gear . N ever use on public roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: without proper trai ning or instruction; at speeds too fast for your skil[...]

34 Safety Safety Labels and Locations Discretionary W arning W ARNING Never operate this A TV on HILLS steeper tha n 15 degrees 15 ° . T o p revent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill. REVERSE operation ca n be dangerous even at low speeds. S teering be comes difficult. T o prevent lo ss of control,[...]

35 Safety Safety Labels and Locations Tire Pressure W arning (Outlaw 90) W ARNING Improper tire pressure or overlo ading can cause lo ss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 3.0 psi ( 20.7 kPa) Rear: 3.0 psi (20.7 kPa) • Maximum Weight Cap acity 180 lbs. (81.7 kg) 7175503 Ti re Pressure [...]

36 Safety Safety Labels and Locations No Passenger W a rning W ARNING NEVER ride as a p assenger . Passengers can cause a loss of control, resulting in SEVERE INJUR Y or DEA TH. 7175378 + +[...]

37 Safety Safety Labels and Locations Spor t sman 90 Rack W arning W ARNING • DO NOT TOW . V ehicl e damage or tipo ver may result causing severe injury or death. • Maximum Rack Loads: Front 15 lbs. (7 kg) Rear 30 lbs. (14 kg) 7174556 + +[...]

38 Safety Safety Labels and Locations Clutch Cover W arning W ARNING NO STEP • Moving part s hazard under belt-cl utch 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 e[...]

39 Y outh Section[...]

40 Know Y our A TV PA R E N T S : Polaris Y outh A TVs are equippe d with a speed control system to allow adults to limit the speed of the vehicle for the rider's sk ill and experience. More information on speed limiting functions can be foun d beginning on page 126. These units are not designed for adult use. Se rious da mage to the vehicle m[...]

41 Know Y our A TV Before you have an adult start the engine for you for the first time, let's learn 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 of f quickly . The button must be up before yo u can st art the engine again. 2. Horn Button - Press the horn [...]

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 t he kick-start lev er with your foot to start th e 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 you r A TV . Read about how t[...]

43 Know Y our A TV 6. Gas Cap - The gas cap has to be taken of f when an adult puts gas in your A TV . Never take the ga s cap off. 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 an[...]

44 Know Y our A TV 8. Brake Levers - Squeeze the brake levers toward the handleba r 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 sa me time. Always squeeze both brake levers at th e same ti me or you could lose control of the A TV and be ser[...]

45 Know Y our A TV 9. Ignition Switch - The ignition switch key must be tu rned on before pushing the starter button. Y ou can also use this key to turn of f 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 of f your A TV , the tether s[...]

46 Know Y our A TV Let's revie w the three ways to st op the engine of your A TV : 1. Push the engine stop switch down. 2. Pull the tether strap off the A TV . 3. T u rn 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, ev ery time you want to ride you must ha ve an adult help you check some thin gs on y our A TV before starting it. Let's lear n about these things now . n Make sure the throttle[...]

48 Pre-Ride Check n Make sure the brakes do n't stick. Check the brake levers by squeezing them toward the handlebar and then letting go. They should co me right back to wher e they were before you squeeze d. If they go bac k slowly or stay cl ose to the handleb ar , your A TV h as sticky brakes. They must be fixed before you can ride y our A [...]

49 Pre-Ride Check n If you used the storage area under the seat, make sure the seat is locke d in place. n Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been runn ing and it can burn yo ur skin if you touch it. Children must never check the oil on their own. An adult should always be in charge[...]

50 Riding Rules Now you're ready to learn ab out riding your Po laris A T V . There are some things you can do and there are some things you must never do. Rules are very importan t when you're driving an A TV . Adults have riding rules, too. The rules help keep us safe when we ride. X The adult with you is your teacher . Always pay atten[...]

51 Riding Rules X Always wear the right k ind of clothing and safety ge ar when riding your A TV . Helmet: Y our helmet is very important for safe riding. A helmet can prevent a severe head injury . Eye Pr otection: Always wear shatterp roof goggles or a helmet face shield, and alwa ys keep them clean so you can see where you're driving. Glove[...]

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

53 Riding Rules X Never ride alone. An adult should always be watc hing you in case you need help. Always drive within the sight of an adult. X Never ride on public trails. X Don't ride your A TV on roads or over railr oad tracks. Y our A TV makes noise that will keep you from hearing cars, trucks or trains that may be comi ng towards you. X D[...]

54 Respect your A TV ; respect your environment; and you will earn the respect of everyone. Enjoy riding your new P olaris 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 ord ering a Polaris key blank (u sing your ke y number) and mating it with one of your existing keys. The ignition switch must be re[...]

57 Features and Con trols Main Key Switch T urn the key clockwise to the ON position before starting the engine. T o avoid draining the battery , always turn the key to the OFF position when the en gine is not running. Always remove the ignition key when the vehicle is not in use. Key Ke y OUTL AW SPORTSMAN[...]

58 Features and Controls Engine S top Switch The engine will not start or run when the stop switch is down, in th e OFF positi on. 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 v[...]

59 Features and Con trols Horn Button Use the horn for emer gencies and to let others know you’re near . Engine S t art Button The start but ton is located s lightly above the choke lever . 1. Attach the tether strap securely to th e vehicle and to the rider's right wrist. 2. Shift the transmission to neut ral. The neutral light will come on[...]

60 Features and Controls Throttle Controls Operating an A TV with sticking or improperly opera ting throttle controls could cause an accident and lead to severe injury or death. Never start or operate a n A TV with a sticking or impro perly operating throttl e. Always contact your dealer for service if throttle p roblems arise. Failure to check or [...]

61 Features and Con trols 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 w ith an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable sho[...]

62 Features and Controls Shif t Lever T o change gears, stop the A TV . W ith 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 fun ction. See your dealer if you experience any sh[...]

63 Features and Con trols Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The ri ght lever controls the front brakes. W ARNING! Applying onl y one brake could cause lo ss of control and result in serious inj ury or death. Always apply both brakes at the same time. [...]

64 Features and Controls Brakes Pa r ki n g B r a k e 1. Squeeze the left brake leve r . 2. Push the parkin g 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 when[...]

65 Features and Con trols Light s Polaris Y o uth A TVs are not equippe d with lights that are designed fo r driv ing in the dark. Do n ot operate this A TV a fter dark. Use caution and drive at reduced speeds in cond itions of reduced visibility . This A TV is designed for off-road use only . Do not operate this A TV on stre ets or highways. Indic[...]

66 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unlea ded gasoline with a minimum pump octa ne of 87. Refer to the specifications sec- tion beginning o n page 162 for fu el tank capacity . Gas Cap[...]

67 Features and Con trols 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 transpor ting. ON: F or normal operation. RES: F or 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 [...]

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 en gine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Lock th e parking b rake. 4. Fold out the kick-start lever on the left side of the A TV . T[...]

69 Operation Failure to operate the A TV properly can result in a co llision, loss of control, a ccide nt or overturn, which may result in se rious injury or d eath. Read an d unde rstand all safet y warnings ou tlined i n the sa fety section of this owner ’ s manual. Break-in Period The break-in period for your new Polaris 4-cycl e A TV is defin[...]

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 oi l level. Add the recommended o il as needed. Maintain the oil level in the proper range. See page 109. 3. Drive slowly at first. Select an open area t hat allows room to familiarize yourself wi t[...]

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 ma intenance at the end o f the break-in pe riod. Item End of Break-In Remarks See Pa g e Engine oil change Perform break-in oil change 110 Oil pre-filter screen Clean [...]

72 Operation Pre-Ride Inspection Failure to inspect and verify that the A TV is in safe operating co ndition 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. Pre-Ride Checklist Item Remarks P age Brake system / lever travel Ensure proper operation 129, 13[...]

73 Operation Pre-Ride Inspection Pre-Ride Checklist Item Remarks P age Throttle Check for proper operation 47, 60, 61 Engine stop switch Check for proper fun ction 58 Daytime running lights (if equip ped) Check for proper operatio n 149 Brakelight Check for proper o peration 147 Air filter , pre-filter Insp ec t, clean or replace 140 Drive chain Ch[...]

74 Operation Safe Operation Practices 1. Complete the re commended safety training before operating this vehicle. See page 8. 2. Do not allow any one under 12 years of age to operate this vehicle. 3. Never carry a passenger on this A TV . 4. Engine ex haust fumes are poisonous. Never start the engine or let it run in an enclosed area. 5. Operate th[...]

75 Operation Safe Operation Practices 7. Drive in a mann er appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hand s from the han- dlebars wh ile operating, an d always keep both feet on the footrests. 8. Never consum e alcohol or drugs before o[...]

76 Operation S t arting the Engine NOTICE: Operating the A TV immediatel y after starting coul d cause engine damage. Allow the en gine to warm up for several minute s before operating. 1. Shift the transmission to neutral. 2. Lock th e parking b rake. 3. T urn the fuel valve on. 4. Sit on the vehicle. Attach the tether strap to the A TV and to you[...]

77 Operation S t arting the Engine 7. T urn the ignition key to ON. 8. Squeeze the rear brake lever and press the st arter button. The rea r brake lever must be engaged or the engine won 't start. 9. Do not press the throttle while starting the engin e. Activat e the sta rter for a maxi mum of five seconds, releasing the button when the en gin[...]

78 Operation S topping the Engine 1. Release the throttle completely . 2. Apply the brakes un til the vehicle stops mo ving. 3. Shift the transmission to neutral. 4. S top the engine. There are three ways to stop the engine: • T urn the key off . • Push the engine stop switch down. • Pull the tether strap off the A TV . 5. Lock th e parking b[...]

79 Operation Driving Procedure 1. Sit upright with both feet on the footrests and both hands on th e handleb ars. 2. Shift the transmission to neutral. 3. S tart the engine and allow it to warm up. 4. Check you r surroundings and determi ne your path of travel. 5. Squeeze the left brake leve r . 6. Shift the transmission to the desired gear . 7. Sl[...]

80 Operation Making T urns Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that th e 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 vehi cle. 2. Always avoid ba cking downhi ll. 3. Back slowly . 4. Apply the bra kes 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 grav el, or during freezing weather , follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down wh en entering slippery areas.[...]

83 Operation Driving on Slippery Surfaces 3. Maintain a high level of alertness, readin g 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 shifting 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, fo llow 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 uph ill. 7. Proceed at a steady rate of speed and thro ttle 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 obstacle, a sharp drop, or another vehicle or person could be on [...]

86 Operation Driving on a Sidehi ll (Sidehilling) Driving on a sideh ill is not recom mended. Imprope r procedure co uld 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 [...]

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

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

89 Operation T urning Around on a Hill 7. Lock the parking brak e 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 m[...]

90 Operation Parking on a Hill or Incline A void parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Lock th e parking b rake. 3. Always block the rear wheels o n the downhill side as shown in the illus- tration. 4. T urn the fuel valve off.[...]

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 throug h shallow water . The recommended maximum depth for your A TV is below the bottom of the footrests. Follow these precautions when operating through wa ter: 1. Determine water depth and current before entering water . 2. If crossing a stream, choose a crossing where both banks [...]

93 Operation Driving Through W ater 4. After driving through water , dry the brakes by applying light pressure to the levers (while moving) until braking action is normal . If you do not perform this procedure, your brakes may be ineffective. NOTICE: Serious engine damage can result if the vehi cl e is n ot thoroughly inspected after operatin g in [...]

94 Operation Hauling Cargo The Sportsman 90 was designed with racks to ca rry small loads. Read and follow all of the instructions for hauling car go on the followin g pages. Never carry car go on the Outlaw 90. Overloading the vehicl e or carrying cargo impro perly can alter vehicl e handling and may cause loss of control, which can result in seri[...]

95 Operation Hauling Cargo • Never exceed the weight capacities for the vehicle. Capacities are listed in the specificati ons section beginning on page 162. • Secure all cargo before d riving. Loose cargo may mo ve or shift, which could cause loss of control or a tipover . Use suitable tie-down s or rope to secure th e cargo. Do not allow cargo[...]

96 Emission Control Systems Noise Emission Control System Do not modify the engin e, intake or exhaus t components, as doing so may affect compliance with U.S.A. EP A noise control requi rements (40 CFR 205) and local noise level requi re- ments. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spa rk arrestor that was tested and[...]

97 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicl e are controlled by engine design, including factory-set fuel delivery and ignition. The en gine and related compon ents must be main- tained at Polaris specifications to achieve optimal pe rformance. Engine idle speed is the only adjustment Po[...]

98 Maintenance Periodic Maintenance Chart T o help you perform routine main tenance, a tool kit is provid ed in the storage compartment under the seat. Maintenance intervals in the fo llowing chart s 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 i[...]

99 Maintena nce Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts 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, ha ve a qu[...]

100 Maintenance Periodic Maintenance Chart Improperly performing the pr ocedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an autho rized Polaris dealer perform these services. Maintenance Chart Ke y X Perform these operations more often under se vere use, such [...]

101 Maintena nce Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) Q Steering -- Daily -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Check- list. 72 X F ront suspension -- Daily -- X Rear suspension -- Daily -- Tires -- Dai ly -- X[...]

102 Maintenance Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) Drive chain -- Daily -- Inspect daily; adjust an[...]

103 Maintena nce Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) Battery 20 Monthly 200 (320) Check terminals; clean; test 150 X Engine oil change 30 6 M 300 (4 80) Drain and change the oil 110 X T ransmission oil 40 12 M 400 (640) Drain and change the oil 114 X Oil pre-filte[...]

104 Maintenance Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) E Carburetor air intake ducts/flange 50 6 M 500 [...]

105 Maintena nce Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) X Wiring 100 1 2 M 1000 (1600) Inspect for wear , routing, security; apply dielectric grease to connec- tors subjected to water , mud, etc. -- Q Clutches (drive and driven) 100 12 M 1000 (1 600) Inspect; clean; [...]

106 Maintenance Lubrication Guide X Perform these procedures more often fo r vehicles subject ed to severe use Item Lube Method Engine Oil P olaris Syntheti c Y outh Oil or Synthetic SAE 40 See page 108. Gearca se (T ra nsmission ) Oil Level Premium AGL Synthetic Gearcase Lub e See page 114. Drive Chain P olaris Chain L ube or SAE 80/90 See page 13[...]

107 Maintena nce Lubrication Guide Grease Po ints Grease P oints[...]

108 Maintenance Engine Oil Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Peri odic Maintenance Chart beginning on page 98. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 16 6 for the part numbers of Polaris products. NOTICE: Mixing brands or [...]

109 Maintena nce Engine Oil Check Maintain the oil level w ithin 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 clo th. 3. Reinstall the dipstick completely . 4. Remove the dipstick and check the oil level. Tip : A rising oil level between checks in cool[...]

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

111 Maintena nce 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 th e screen to air dry . 8. Clean the pre-filter plug. Install a new sea ling washer on the plug . The sealing surfaces on the [...]

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 beginni ng on page 162 for capacities. 12. Reinstall the dipstick. 13. S tart the engine. All ow it to idle for one to two [...]

113 Maintena nce Fuel Filter The Polaris A TV is equipped with an in-line fuel filter . This f ilter should be replaced by your dealer at the intervals recomm ended in the Periodic Maintena nce 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 pa ge 98. Polaris reco mmends the use of A[...]

115 Maintena nce 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. Ma intain the oi l level at the bott[...]

116 Maintenance S p ark Plugs Refer to the specifications section beginning on page 1 62 for spark pl ug and gap specifica- tions. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Alwa ys use Polaris-recomme nded spark plugs. Spark plug condition is indicativ e of engine operat ion. The spark plug firing end condition [...]

117 Maintena nce S p 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 whit e. A white insulato r tip indicates overh eat- ing, caused by use o[...]

118 Maintenance Cylinder Head T orque Have your dealer ch eck the A TV cylinder head fo r proper torque at the first service, or after 25 hours. V ehicle Immersion If the vehicle tips or overturns in water deeper than the footrest level, or if t he engine stops during or after operating in water , restartin g WILL result in serious engine da mage. [...]

119 Maintena nce V ehicle Immersion 5. Loosen the carburetor drain screw . 6. T urn the engine over several times us ing 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 pro[...]

120 Maintenance Const ant V ariable T r ansmission (CVT) System Failure to comply with the instructions in this warning can resul t in severe injury or death. Do not modify any component of the CVT system. Doin g so may reduce its strength so that a failure may occur at a high speed. The CVT system has b een precision balanced. An y modificati on w[...]

121 Maintena nce CVT Drying There m ay be so me instan ces when water is a ccidently ingested into the CVT system. Use the following instructions to dr y it out before operating. The dr ain plug is located on the bot- tom of the CVT cover . 1. Remove the drain plug. Allow the water to drain. Reinstall the d rain plug. 2. Shift the transmission to n[...]

122 Maintenance S p ark Arrestor T o remove accumulated carbon, clean the spa rk arrestor at the interv als recommended in the Periodic Maintenance Char t beginni ng on page 9 8. Failure to heed these warnin gs could result in seri ous injury or death. • Do not perform service on the spar k arrestor while the system is hot. Allow components to co[...]

123 Maintena nce S p ark Arrestor 1. Remove the six bolts and remove the arres- tor from the end of the muf fler . 2. Use a no n-synthetic brush to clean the arrestor 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 ar[...]

124 Maintenance Carburetor Y our Polaris A TV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temp eratures of +40 degrees F . (4 degrees C.) or higher . Above 6000 feet (1 800 m) the engine air/fue l mixture becomes overly rich and the engine loses approximately 3% of its power for eac[...]

125 Maintena nce Carburetor If the engine idle speed is not satisfactory , an d all other conditions are favorable, the carbure- tor can be adjusted. 1. S tart the engine. 2. Lock th e parking b rake. 3. Allow the engine to run for a pproximately five minutes. 4. Adjust the carburetor idle screw either in or out until the desired idle RPM is reache[...]

126 Maintenance S peed Control System Per ANSI / SVIA-1-2001 (sec. 6.1.3) AS DELIVERED TO THE CONS UMER, the speed of youth mo dels is re stricted to unde r 10 MPH for the 50cc models and under 15 MPH for the 90cc models. The dealer CANNOT , under any cir cumstances, either prior to the sale or later , ev en at the consumer's r e quest, r emov[...]

127 Maintena nce S peed Control System Throttle Sto p 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. Periodic ally check the throttle freeplay . It should be ke pt 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[...]

129 Maintena nce Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the inte rvals rec- ommended in the Pe riodic Maintenance Chart beginning o n page 98. If the free- play isn’ t at specification, adjust the freeplay as outlined on the following pages. Brake F reeplay Specifications Model F ront Brake Rear Brake 90cc Mod[...]

130 Maintenance Brake Freeplay F ront 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 nu[...]

131 Maintena nce Brake Freeplay F ront Brake Adjustment 6. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 7. When y ou begin to feel a slight drag in wheel ro tation, loos en the ad juster nut one full turn. 8. V erify that the right-hand brake functions correctly . 9. V erify that brake [...]

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 ve hicle 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 brak[...]

133 Maintena nce Brake Lever T ravel Check brake lever travel at the intervals re commended in the Period ic Maintenance Chart beginning on page 98. When freeplay specificat ions can no longer be obtained through adjustment as outlined on th e preceding pages, use the followi ng information to determine when to service the brakes. Service the brake[...]

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. Th e recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. W ARNING! Severe injury or death can result from improper toe align ment and adj ustment. Do not at tempt to adjust tie rod alignment. All ti e rod adjustmen ts sh[...]

135 Maintena nce To e A l i g n m e n t 4. Measure the distance from the st ring to the rim at the front (1) and rear (2) of the front rim. The rear measuremen t should be 1/16 "-1/ 8" (2-3 mm) more th an the front measure- ment on each sid e of the vehicle to obtai n the recomm ended 1/8" to 1/4" (3-6 mm ) toe out alignment. 5.[...]

136 Maintenance S teering Inspection Check the steering a ssembly pe riod ically for loose nuts and b olts. 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 S pring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease [...]

137 Maintena nce Drive Chain Lubricate the drive chain with Polaris chain spra y lube or an approved chain lube at the gen- eral lubrication interval specified in the Peri odic Maintenance Chart beginning on page 98 . Lubricate more often under severe use, such as in dirty or wet conditions. See page 166 for the part numbers of Polaris products. NO[...]

138 Maintenance Drive Chain Slack 1. Check the amou nt of chain slac k by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. Collapse the suspens ion with an adjustable (buckle type) tr ailer tie- down strap. Fasten the strap around the axle and rear bumper tube. 3. T ighten the strap until a straight line can be dra[...]

139 Maintena nce Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. T urn the chain adjus ter 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 adjust er stud securely while tightening the nut to avoid break[...]

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 ash the foam fi lter in warm soapy water , then rinse and let dry . If the filter is damaged, install a new foam filter . 4. Apply a commercially av ailable foam filter lubricant to the foam [...]

141 Maintena nce 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 causing rapid wear and severe d amage to the engine.[...]

142 Maintenance Handlebar Adjustment Improper adjustment of th e handleba rs or incorre ct torquing of the ad juster blo ck tightening bolts can cause limited steeri ng or loosening of the ha ndlebars, resu lting in loss of control and possibl e serious personal injury or death. Follow th e adjustment proc edures exactly , or see your Polaris deal [...]

143 Maintena nce Ti r e s Operating your A TV with worn tires, imprope rly inflat ed tires, non-standard tires or improperly inst alled tires will affect vehicle handling and co uld cause an accident resul ting in serious inju ry or death. Al ways follow all tire maintenance proced ures as outline d in this manua l and on the labels on the vehi cle[...]

144 Maintenance T ire T read Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. S top the engine an d 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 bol ts and remove the wheel. 1/[...]

145 Maintena nce Wheel Inst allation 1. Lock th e parking b rake. 2. Place the wheel in the correct position on th e 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 veh icle to the grou nd. 5. Securely tighten the [...]

146 Maintenance Axle and Wheel Nut s All nuts with a cotter pin installed must be service by an authorized Polaris dealer . Wheel Hub Ti ghtening Front wheel bearing tightness an d spindle nut retention are cr itical componen t operations. All service must be performe d by your authorize d Polaris dealer .[...]

147 Maintena nce T ail Light Lamp Replacement If the brakelight do esn't work, the lamp may need to be replace d. 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 operatio n. 4. Reinstall the lens cover . Scre ws 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 re install al[...]

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

150 Maintenanc e Battery Improperly connecting or disconn ec ting battery cables can result in an explosion and cause seriou s injury or death. Wh en removing the battery , always disconnect the negative (black) cable first. When reinstalling the battery , always connect th e negative (black) cable la st. The battery in your Polaris A TV is a seale[...]

151 Maintena nce Battery Battery Removal 1. Disconnect the hold-down stra ps 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 o ut of the A TV .[...]

152 Maintenance Battery Battery Installat ion and Connections Always install a fully char ged battery . Using a new battery that has not been fully char ged can damage the battery and result in a shorter lif e. It can also hinder vehicle performance. If recharging is necessary , use a .5 amp battery charger 1. Set the battery in its holder . 2. Con[...]

153 Maintena nce Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remov e 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 month during storage and rechar ge as needed to maintain a full charge. Cleaning Keep[...]

154 Maintenance Cleaning W ashing t he A TV The best and safe st way to clean your Polaris ve hicle is with a garden hose and a pail of mild soap and water . 1. Use a professional-type washing cloth, cleani ng the upper body first and the lower parts last. 2. Rinse with clean water frequ ently . 3. Dry su rfaces with a cham ois to preve nt water sp[...]

155 Maintena nce Cleaning W ashing t he A TV If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may d amage components and could remove paint and d ecals. A void directing the water stream at the following items: • Wheel bearin gs • Radiator • T ransmission sea ls •B r a k e s • Cab[...]

156 Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishi ng the finish on your Polaris vehicle. Fo llow the instructions on the container . Polishing Tips • A void the use of automotive products, so me of which can scratch the finish of you r vehi- cle. • Always use clean cloths an d pads for[...]

157 Maintena nce Sto r a g e Exterior Make necessary repairs and c lean the vehicle as recommended. See page 153. Battery Storage Remove the battery from th e vehicl e, ensure that it's fully ch arged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storag e an d recharge as needed to maintain a full c[...]

158 Maintenance Storage Stabilize the F u el Polaris Carbon Clean is a fuel stabilizer and fu el system dryer . It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fu el T rea tment or Pola[...]

159 Maintena nce Sto r a g e Engine Oil Change the oil. See page 1 10. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner a nd air filter . Clean the air box. Drain the sedi- ment tube. Fluid Levels Inspect fluid levels. Change fluids as reco mmended in the Period ic Maintenance Chart beginning o n page 98. • T ransmission Oil ?[...]

160 Maintenance Sto r a g e Lubricate Inspect all cables and lubricate all areas of the vehicle as recomme nded in the Periodic Main- tenance Chart beginning o n page 98. Storage Area/Cove rs 1. Make sure tire pressure is at specification. 2. Using suitable su pports unde r the frame, raise the vehicle slightly so that the tires are not touching th[...]

161 Maintena nce T ransporting the A TV Follow these procedures when transporting the A TV . 1. S top the engine. 2. Place the transmission in gear . 3. Lock th e parking b rake. 4. Secure the fuel cap, oil cap and seat. 5. T urn the fuel valve off. 6. Always tie the frame of the A TV to the tran sporti ng unit securely w ith suitable straps or rop[...]

162 S pecifications Outlaw 90 Rider Capacity/M aximum Weight 1 Rider/1 80 lbs. (8 1.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication We t Sump Oil Capacity 30 oz. (900 ml) F u el Capacit y 1.7 gallo ns (6.4 lite rs) F uel Reserve Capacity .23 gallons (.86 liters) Starting Electric with kick-st art backup Drive System Auto[...]

163 S pecifications Outlaw 90 F r ont/Rear Brakes Dru m P arking Brake Mechanic al Lock F ront Tires 19 x 7 - 8 (3 psi/2 0.7 kPa) Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kP a) Dry W eight 270 lbs. (122.4 kg) Length/Width/Height 61.25" (1 56 cm) / 36.75" (93 cm) / 38.5 " (98 cm) Wheel Base 41.5" (105 cm) Ground Cleara nce 4" (10[...]

164 S pecifications Sportsman 90 Rider Capacity/M aximum Weight 1 Rider/1 80 lbs. (8 1.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication We t Sump Oil Capacity 30 oz. (900 ml) F uel Capacity 2 gallons (7.7 liters) F uel Reserve Capacity .22 gallons (.85 liters) Starting Electric with kick-st art backup Drive System Automat[...]

165 S pecifications Sportsman 90 F ront Rack Capacity 15 lbs. (7 kg) Rear Rack Capacity 30 lbs. (14 kg) F r ont/Rear Brakes Drum P arking Brake Mechanic al Lock F ront Tires 19 x 7 - 8 (3 psi/2 0.7 kPa) Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kP a) Dry W eight 289 lbs. (131 kg) Length/Width/Height 61.75" (1 57 cm) / 36.75" (93 cm) / 38.5 &quo[...]

166 Polaris Product s P art Number Description Engine L ubricant 2876248 Synthetic Y outh Oil (qt/.95 l) 2876249 Synthetic Y outh Oil (gal/3.8 l) 2872175 Semi-Synthetic 20W -40 Oil (qt/.95 l) 2872176 Semi-Synthetic 20W -40 Oil (gal/3.8 l) 2870791 Fogging Oil, Aerosol Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic G earcase Lubric[...]

167 Polaris Product s P art Number Description Grease 2871322 All Se ason Premium Grease (3 oz./89 ml) 2871423 All Se ason Premium Grease (14 oz./414 ml) Miscellaneous Additive s 2871326 Carbon Cl ean Plus[...]

168 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 Pos sible Cause Solution Out of fuel T urn the fuel valve to reserve, refuel Clogged fuel valve or filter In spect and clean or replace W ater is present in fue l Drain t he fuel syst em and refue[...]

169 T roubleshoot ing Engine Doesn’t T urn Over Engine Pings or Knocks Possible Caus e Solution Low battery voltage Rechar ge ba ttery wi th .5 amp char ger Loose battery connections Chec k all connectio ns and tighten Loose solenoid connections Chec k all connectio ns and tighten Possible Caus e Solution Poor quality or low octane fu el Replace [...]

170 T roubleshooting Engine Backfires Possible Caus e Solution 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 [...]

171 T roubleshoot ing Engine Runs Irregularl y , St alls or Misfires Possible Caus e Solution Fouled or defective spark plugs Inspec t, 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 connect ions Check all connection[...]

172 T roubleshooting Engine Runs Irregularl y , St alls or Misfires Possible Le an F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean the fuel system Low octane fuel Replace with recommende d fuel Clogged fuel filte r Replace f ilter Incorrect jetting See your Polaris dealer Possible Rich F uel Mixture Cause Solution O[...]

173 T roubleshoot ing Engine S top s or Loses Power Possible Caus e Solution Out of fuel T urn the fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace W ater prese nt in fuel Replace with new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Fouled or defective spark plugs Inspec t, clean and/or repla[...]

174 Wa r r a n t y LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of t he Polaris All T errai n V ehicle (A TV) agai nst defects in ma terial or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warra nt[...]

175 W arranty W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris l imited warranty e xcludes any failures t hat are not caused by a defect in material or workmanship. This warranty does not cover accident al damage, normal wear and tear, a buse or improper ha ndling. Th is war- ranty also does not cover any A T[...]

176 Wa r r a n t y W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLU DING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCL AIMS ALL EXPRESS W ARRAN[...]

177 W arranty HOW TO OBT AIN WARRANTY SERVICE If your A TV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris A TVs. When requesting warranty service you mu st present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). [...]

178 Wa r r a n t y EXPORTED VEHICLES EXCEP T WHERE SP ECIFICALL Y REQUIRE D BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA TION. This policy does not apply to vehicles that have received authorization for export from Po laris Industries[...]

179 W arranty EXPORTED VEHICLES How to Get Ser vice I f Y ou 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. V ehicles importation rules vary c onsiderably from country to country . Y ou may be required to present do cumentat ion of your mov[...]

180 Wa r r a n t y U.S.A . EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warrant y is in addition to the Po laris standard limite d warranty for this vehicle. Polaris warrants that this ve hicle is; (1 ) designed, built, and equipped to conf orm at the tim e of initial sale [...]

181 W arranty U.S.A . EP A Emissions Limited W arranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products. THE REMEDIES SET FOR T H IN THIS LIM- ITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF [...]

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

183 Maintenance Log DA TE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 100 Hours 120 Hours 150 Hours[...]

184 Maintenance Log DA TE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

185 Maintenance Log DA TE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

186 Index A Accessories . . . . . . . . . . . . . . . 161 Age Restrictions . . . . . . . . . . . . . 13 Air Filter . . . . . . . . . . . . . . 140 - 14 1 Axle and Wheel Nuts . . . . . . . . . 146 B Battery . . . . . . . . . . . . . . . 150 - 153 Installation and Connections 152 Removal . . . . . . . . . . . . . . 151 Storage . . . . . . . . . . . 1[...]

187 Index G Gas Cap . . . . . . . . . . . . . . . 43 , 66 Gasoline Handling . . . . . . . . . . . 15 Gearcase Capacity . . . . . . . . . . 115 Gloves . . . . . . . . . . . . . . . . . . . 11 H Handlebar Adjustment . . . . . . . 142 Hauling Cargo . . . . . . . . . . . . 94 - 95 Helmet . . . . . . . . . . . . . . . . . . . 10 Horn . . . . . . . . . .[...]

188 Index S Safety Labels and Locations . . 32 - 38 Safety Training . . . . . . . . . . . . . 8 - 9 Safety Warnings . . . . . . . . . 13 - 31 Age Restrictions . . . . . . . . . . 13 Carrying a Passenger . . . . . . . 17 Crossing Hillsides . . . . . . . . . 23 Descending Hi lls Impr operly . 22 Excessive Speeds . . . . . . . . . 19 Exposure to Ex ha[...]

189 Index S Switches Engine Start Button . . . . . . . 59 Engine Stop Switch . . . . 41 , 58 Horn Button . . . . . . . . . . . . 41 Ignition Swi tch . . . . . . . . . . 45 Main Key Switch . . . . . . . . . 57 Tether Switch . . . . . . . . . . . 45 T Tail Light . . . . . . . . . . . . . . . . . 147 Tether Strap . . . . . . . . . . . . . . . . 45 Thr[...]