Polaris Sportsman 90 manual

Read this manual car efully . It c ontains im port ant saf et y infor mat ion. Scr ambler 50 - No one under t he age of 6 s hould ride t his vehic le. Sport sm an 90 and Scr ambler 90 - No one under t he age of 12 s hould ride t hese vehic les. 2001 YOUTH A TV MO DELS Owner ’ s Safety and Maintenance Manual[...]

The engine exhaust from this product contains chemical s known to cause cancer , bi rth defects or other reproductive harm. W ARNING[...]

Indica tes a potential hazar d which could result in severe injury or death.[...]

Part No. 9916424 Improp er A TV use can resu lt in SEVERE I NJUR Y or DEA TH Always use an appr oved helmet and prot ective gear Never use on publi c roads Never carr y passengers Never use with drugs or alcohol NEVER operate: without proper t raining or inst ruct ion; at speeds t oo fas t f or your sk ills or the conditi ons; on public roads - a c[...]

i FOREWORD Congr atulations and thank you from Polari s Industries Inc . for pur chasing one of our all -terr ain vehi cles ( A TVs). Built wi th Ameri can engineer ing and m anufacturi ng know - how , it i s designed to pr ovide super ior r iding com fort, enj oyment, and safety . Thi s manual i s furni shed to ensure that the oper ator and par en[...]

ii PROTEC T YOUR SPORT Know all l ocal, state/prov ince ridi ng laws; Res pect your vehi cle; Respec t the envir onment; and Y o u will gain t he re spe ct of o th ers. W e also adv ise you to st rict ly foll ow the rec ommended m aintenance program as out- li ned. Thi s preventi ve maintenanc e program is desi gned to ensur e that all cr itical co[...]

iii INT RODUCTOR Y SAFET Y M ESSAGE TO P ARENT S AN A TV I S NOT A TOY AND CAN BE HAZARDOUS TO OPE RA TE. An A TV handles differe ntly from o th er ve hicle s in clud ing mot orcycle s an d cars. A collisio n o r rollo ver can occ ur quick ly , even duri ng routine maneuver s such as tur ning and driv ing on h ills or over obstac les, if you fail t[...]

iv • Alw ays foll ow the age guidel ines for your m achine. Y outh A TVs are des igned and intended for use by chil dren in tw o age groups. The Scr ambler 50 i s for c hildr en not les s than 6 years of age. The Sc rambl er 90 and the Sports man 90 a re for chi l- dren not l ess than 12 year s of age. No chi ldren under the age of 16 should ride[...]

v • Never attem pt wheeli es, jumps or other stunts. • Alw ays inspect your A TV each tim e you use it to mak e sure i t is i n safe operating conditi on. Al ways fol low the i nspection and m aintenance proc edures and sched- ules desc ribed in thi s manual. • Alw ays keep both hands on the handlebars and both feet on the footrest s of the A[...]

vi • Alw ays follow pr oper procedures for c limbi ng h ills a s de scrib ed in th is m anual . Che ck the t erra in care fu lly be fo re you st art up a ny hill. Ne ve r climb hills with exces- siv ely sli ppery or loose surfac es. Shift your wei ght forw ard. Never open the throttle suddenl y or make sudden gear changes. Never go over the top o[...]

vii • Alw ays use pr oper proc edures if you stall or rol l backw ards when c lim bing a h ill. T o avoid s talli ng, maintai n a steady speed w hen clim bing a h ill. If you stall o r ro ll backw ards, fol low t he special procedur e for br aking descr ibed in thi s manual . Dis- mount on the uphi ll s ide or to ei ther side i f poi nted strai g[...]

viii • Alw ays use the si ze and type tir es speci fied in thi s manual . Alw ays mai ntain pr oper tir e pressur e as descr ibed in thi s manual. • Never modify an A TV thr ough impr oper ins tallati on or use of acc essori es. • Never exceed the stated l oad capacity for an A TV . Car go should be proper ly dis trib- uted and secur ely atta[...]

ix Polar is hereby i nforms you that the warr anty on your A TV is term inated if any such equipm ent has been added to the A TV or any m odificati ons have been made to the A TV w hich inc rease its speed or power . W e also adv ise you to stri ctly fol low the recomm ended m aintenance pr ogram outlined in thi s manual. Thi s preventi ve mai nten[...]

x T ABLE OF CONTENTS RIDER’S SECT I ON R-1 - R- 20 ............................................... UNDERST ANDI NG W A RNING S 1-4 .......................................... GENERAL SAFETY AND DESCRIPTION O F LABELS 5-18 ..................... DAIL Y P RE-RI DE CHECK 20-21 ............................................. OPE RA T IO N WARNINGS 22-46 [...]

xi T ABLE OF CONTENTS PVT SYSTEM OPER A T I ON 104-105 ....................................... BA T T ERY 106-1 1 1 ....................................................... NOISE EMISSI ON CONTROL SYST EM REGULA T ION 1 12-1 14 ............... MAI NTE NANCE 1 15-161 .................................................. SPECIFI CA T I ONS 162-168 ......[...]

R- - 1 RIDER’S SECTION[...]

R- - 2 KNOW YOUR MACHINE P ARENTS: Review the information in this manual with any child who may be operating the A TV . It is up to you to teach your chil d the proper and safe way to ride an A TV . Y ou m ust set boundaries and adhere to them, keeping your child’ s safety foremost in your mind. Never allow your child to operate this machine with[...]

R- - 3 KNOW YOUR MACHINE Pay attention w hen you see this symbol.: This is the sa fet y aler t sy mbol. When you see this sy mbol on your ma chine or in this m anual it m eans P A Y A TTENTION . If you don’t, you co u ld g et hu rt very bad ly o r even k illed. Y our sa fety is involv ed![...]

R- - 4 KNOW YOUR MACHINE Before you have an adult s tart the engine for you for the first time, let’ s learn about the controls on your new machi ne. 1. Engi ne Stop Swi tch - When the engine is runni ng, you can slide this button to the left or the right and the engine will stop. T he stop switch must be in the “middle” posi tion to start th[...]

R- - 5 KNOW YOUR MACHINE 3. Kick Starter (B ) - If your battery is too weak to start your machine, you can push on this wi th your foot to start the engine. Have an adult show you how this works. There is more information on how to use the kickstart on page 69. 3 B[...]

R- - 6 KNOW YOUR MACHINE 4. Gas Cap - This is where the gas goes that will run your A T V . Y our A T V will not run without gas. Only adults should fill the gas tank. 1 4 Alw ays have an adult put gas in your machine.[...]

R- - 7 KNOW YOUR MACHINE 5. Brake Lever (C) - Squeeze this towards the handle bar to make your A T V slow down or stop. The right hand lever (C-1) control s the front brake. T he left hand lever (C-2) controls the rear brake. T o slow down or stop, squeeze both brake handles at the same ti me. 5 C- 1 C- 2 Always appl y both brakes at the same time [...]

R- - 8 KNOW YOUR MACHINE 6. Ignition S witch - This k ey must be turned “on” before pushing the starter button. Y ou can also use this key to turn off the engine. Y ou can find it on the Right-hand side of the S cramblers (D) and on the pod of the Sportsman (E ). D E 6[...]

R- - 9 KNOW YOUR MACHINE 7. T ether Strap/ Switch - This must always be attached snugly to your right wrist and your machine w hen you are riding. If you fall of f your A TV , the tether will pull of f the switch and the engine will stop. Put one end o f the teth er strap around your right wrist. The other end must be attached to the A T V . Always[...]

R- - 10 KNOW YOUR MACHINE Let ’ s review th e three ways t o stop your A TV . 1. S li ding the shut off s witc h to the left or r ight. 2. Disconn ecting th e teth er strap will shut of f the engin e. 3. T urning t he key to off will shut o ff the engin e.[...]

R- - 1 1 KNOW YOUR MACHINE 1 2 3[...]

R- - 12 PRE RIDE CHECK Y ou are almost ready to have an adult start your A TV . Before the A TV is started for the first time, you must do a PRE -RIDE CHECK . In fact, every time you ride your A TV you must have an adult hel p you check these things before starting it. Let’s learn about these things now . Make sure the t hrottle doesn’t sti ck.[...]

R- - 13 PRE RIDE CHECK Make sure the brakes don’t stick. Check the brake levers by squeezing them toward the handlebar and then letting i t go. They should come ri ght back to where they were before you squeezed. If they go back slowly or stay on, your brakes are sticking. If you have used the storage area under the seat, make sure the seat is lo[...]

R- - 14 PRE RIDE CHECK Have an adult check the gas level to see if your A TV needs more. Child ren should n ever add t heir own gasoline. This should always be done by an adult. Before anyone adds gasoli ne to your A TV they must read the instructions and w arnings on page 60 in this Owner ’s Manual . Have an adult check the engi ne oil level whe[...]

R- - 15 PRE RIDE CHECK This last check is done with the engine running. Y ou m ust check to make certain that ALL T HREE W A YS TO STOP your A T V are working the way they should. Do you remember what they are? If you cannot list them, go back to page R - - 10 and review . [...]

R- - 16 RIDING RULES Now you are ready to learn about riding a A TV . Y ou will learn what you can do and what you cannot do. T he adult wi th you is your teacher . Y ou must listen and pay attention or you won’t be safe w hen you ride. Remember that safety while you ride i s the most important thing. Let’s learn how to ride! " Y our A TV [...]

R- - 17 RIDING RULES " Always wear the right kind of clothing when you are r iding your A TV . Y ou will need a good helmet with a f ace shield or goggles. W ear a long sleeved shirt or jacket, gloves, long pants, and boots. Make sure your clothing fits properl y . If it is too small, it could keep you from moving easily . If it is too big, i [...]

R- - 18 RIDING RULES " Never ride alone. An adult shoul d always be watching you in case you need help. Always drive w ithin the sight of an adult. " Never r ide on pub lic trails. " Alw ays drive your A TV while sitting down. Keep both hands on the handlebars and keep both feet on the running boards. Y ou must always foll ow the saf[...]

R- - 19 RIDING RULES " Don’t ride your A T V on roads or over railroad tracks. Y our A TV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. " Don’t ride at night. " Learn where there are lakes, ri vers, ponds and ditches in your driving area. Stay aw ay from them. Never ride on fro[...]

R- - 20 RIDING RULES " Never follow another A TV too closely . Always al low lots of time and space to stop your A TV . " Only ride your A TV where you know it is safe to drive. No driving over the flower garden or on the littl e trees you planted. B e careful of the things around you. " Alw ays attach the tether strap to your right [...]

1 UNDERST ANDING W ARNINGS A TTENTI ON: Alw ays foll ow the age guidel ines on the machine. YOU M UST M AKE CER T AIN TH E OPE RA TOR(S) UNDERST A ND ALL W ARNI NGS A ND THE OWNER’S MANUAL BEFORE OPER A TION. KNOW YO UR VE HICLE BE FORE YOU BE GI N RIDING ! . It i s the parent’ s responsi b ilit y to te ach t h eir c hild re n th e p r oper and[...]

2 UNDERST ANDING W ARNINGS Y ou should r eview this i nformati on with your chil d on a regular basis. In the ev ent you purc hased a used Polar is A TV from a party other than a Polar is dealer , safety traini ng can obtained at no char ge from any authori zed Polar is dealer . Fai lure to foll ow the war nings contai ned in this manual can resul [...]

3 UNDERST ANDING W ARNINGS The fol lowi ng precautionar y signal wor ds are used thr oughout this m anual to c onvey the foll owing m essages: This is the safety a lert symbol . When you see this symbol on your mac hine or in this manual , be alert to the potential for per sonal injur y . Y our sa fety is involv ed! Indica tes a potential hazar d w[...]

4 UNDERST ANDING W ARNINGS The fol lowi ng precautionar y signal wor ds are used thr oughout this m anual to c onvey the foll owing m essages: Indicates a potential hazard wh ich may re sult in minor personal inj ury or dama ge to the A TV . NOTE The word “NOTE:” in th is manual will alert you to key infor mation or instr uctions. Indicates a s[...]

5 GENERAL SAF E TY AND DESCRIPTION OF LABEL S NOTE: W arni ng decals have been placed on the vehic le for the protecti on of the operator( s). Read and follow the inst ructi ons on each decal c arefull y . In t he event any decal be- com es il legibl e or comes of f, contact your Polar is dealer for a replacem ent. Any safe- ty decal needing repl a[...]

6 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 1 W ARNING[...]

7 GENERAL SAF E TY AND DESCRIPTION OF LABEL S Improp er A TV use can resu lt in SEVERE I NJUR Y OR DEA TH. Alw ays use an appr oved helmet and protec tive gear; Never use on publi c roads Nev er carry pas sengers; Nev er use wit h drugs or alcohol NEVER oper ate: without pr oper trai ning or ins tructi on; at speeds too fast for your skills or t he[...]

8 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 2 Kids under age 6 s hould NEVER operate this AT V. Kids under 6 have an increased c hance of los ing control, whi ch could resul t in sev ere injury or death. Adult supervi sion is required. Make sure operators follow Owner’s Manual and labels . Make sure operators watch the safety video and pass the[...]

9 SAFETY W ARNING AND OPERA TION DECALS S Kids under age 6 s hould N EVER operate this A TV . Kids under 6 have an increased chanc e of losing control, w hich could result in severe i njury or death. S Adult supervi sion is required. S Make sure operators follow Owner ’ s Manual and labels. S Make sure operators watch the safety vi deo and pass t[...]

10 SAFETY W ARNING AND OPERA TION DECALS 2 Kids under age 12 should N EVER operate this A TV . Kids under 12 have an increased c hance of losing control , which could result in severe injury or death. Adult supervision is required. Make sure operators follow Owner’s Manual and labels. Make sure operators watch the safet y v ideo and pass the A TV[...]

11 GENERAL SAF E TY AND DESCRIPTION OF LABEL S S Kids under age 12 shoul d N EVER operate this A TV . Kids under 12 have an increased chanc e of losing control, w hich could result in severe i njury or death. S Adult supervi sion is required. S Make sure operators follow Owner ’ s Manual and labels. S Make sure operators watch the safety vi deo a[...]

12 GENERAL SAF E TY AND DESCRIPTION OF LABEL S IMPR OPER TIRE PR ESSURE OR OVERLOAD ING can cause los s of control, resul ting in SEVERE IN JUR Y OR DEA TH. TIRE PR ESSURE ( PSI): FRON T 2 REAR 2 max imum w eight capacity (Gro ss V e h icle Weigh t) I NCLUDI NG MA CHINE , DR IVER AND CARGO IS _____ LBS. (F ound on Scrambl er 50 and Scr ambler 90) 3[...]

13 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 4 W ARNING Indica tes a potential haza rd which coul d result in severe injury or d eath.[...]

14 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 5 6[...]

15 GENERAL SAF E TY AND DESCRIPTION OF LABEL S D Operat ion of this vehicl e without t he fi lter el ement will sever ely damage the engi ne. D Clean air f ilt er often, mor e fr equent cleani ng requir ed in dusty condi tions. (on rear of seat ) 6 D Specif ic carburet or jett ing and adjust ments are requi red depending on t emperat ure and alt it[...]

16 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 7 10 8 9[...]

17 GENERAL SAF E TY AND DESCRIPTION OF LABEL S 7 Moving par ts haz ard under belt -c lutc h guard. T o pr event s erious injury , do not oper ate v ehicle wit h guard rem oved. Do not m odify engine or clut ch. Doing so can c ause part f ailure, possible imbalance, and exces sive engine RP M which c an result in ser ious injury or death. DO NOT T O[...]

18 GENERAL SAF E TY AND DESCRIPTION OF LABEL S MANUFACTURED BY: POLARIS IND. INC. DA TE: VIN: TH IS VEHIC L E IS AN AL L T ERR AIN VEH ICL E AN D IS NOT I NTENDE D FOR USE ON PUB LIC ROA DS. CE VÉ HICULE E ST UN VÉHI CULE TOUT TE RRAIN QUI N i EST P AS D ESTIN É À ÊTR E UT ILISÉ SU R LES C HEM INS PU BL ICS. IMPROPER TIRE PRESSUR E OR O VERLO[...]

19 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV wit hout proper ins tructi on. WHA T CA N HAPPEN The ri sk of an acci dent is greatly i ncreased if the operator does not know how to operate the A TV proper ly in dif ferent si tuations and on dif ferent ty pes of terrai n. HOW T O A VOID THE HAZA RD Beginni ng and inexperi enced oper[...]

20 DAIL Y PRE -RIDE I NSPECTION Use the foll owing checkl ist t o veri fy your mac hine is in pr oper worki ng order each ti me you r ide. Item/In spection Pr ocedure 1. T ir es - check condi tion and pressur es 2. Fuel and oil tank s - fill both tanks to their proper l evels 3. Al l brakes - chec k operation, adj ustment. 4. Thr ottle - c heck for[...]

21 DAIL Y PRE -RIDE I NSPECTION 6. Engi ne stop switc h - check for proper func tion 7. W heels - check f or tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotte r pin s 8. D rive c hain - condi tion and sl ack; refer to driv e chain adjus tment 9. Ai r cleaner elem ent - check for dir t; clean or repl ace 10. Steeri ng [...]

22 OPERA TION W ARNINGS POTENT IAL HA ZARD Fail ure to foll ow the age rec ommendati ons for thi s A TV . WHA T CA N HAPPEN Use by childr en of A TVs that are not rec ommended for their age c an lead to sever e injur y or death of the c hild. Even though a chil d may be wit hin the age group for whi ch som e A TVs ar e rec ommended, he or she may n[...]

23 OPERA TION W ARNINGS POTENT IAL HA ZARD Car ryi ng a passenger on thi s A TV . WHA T CA N HAPPEN Greatl y reduces your ab ilit y to ba lan ce a nd co n tro l this A TV . Coul d cause an accident, r esulting in har m to you and/or your pass enger . HOW T O A VOID THE HAZA RD Never carr y a passenger . The long seat i s to allow the operator to sh[...]

24 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV on paved surf aces, includi ng side- wal ks, paths, par king lots, and dr iveway s. WHA T CA N HAPPEN The A TV tir es are desi gned for of f-road us e. Paved sur faces may ser iousl y affect handl ing and control of the A TV , and may cause the vehic le to g o out of control . HOW T O [...]

25 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV on public st reets, roads or highw ays. WHA T CA N HAPPEN Y o u can co llid e with another vehicl e. HOW T O A VOID THE HAZA RD Never operate thi s A TV on any public str eet, road or highway , even a dir t or gr avel one. In many states i t is ill egal to operate A TVs on publi c stre[...]

26 OPERA TION W ARNINGS POTENT IAL HAZARD Oper ating this A TV wi thout wear ing an approved hel met, eye pr otection and pro- tect ive clot hin g. WH A T CAN HAPPEN Operating w ithout an approved helm et increas es your chances of a severe head injur y or death i n the event of an acc ident. Operati ng without ey e protecti on can resul t in an ac[...]

27 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV after consum ing alcohol or drugs . WHA T CA N HAPPEN Coul d seri ously affec t your judgm ent. Coul d cause you to r eact mor e slowl y . Coul d affec t your balanc e and percepti on. Coul d result in an ac cident. HOW T O A VOID THE HAZA RD Never consume al cohol or drugs before or w[...]

28 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV at exces sive s peeds. WHA T CA N HAPPEN Incr eases your chances of l osing contr ol of the A TV , whic h can result in an acci- dent. HOW T O A VOID THE HAZA RD Alw ays trav el at a speed whi ch is pr oper for t he terrai n, visi b ilit y a nd operating conditi ons; and your exper ien[...]

29 OPERA TION W ARNINGS POTENT IAL HA ZARD Attempti ng wheelies , jumps and other stunts. WHA T CA N HAPPEN Incr eases the chance of an accident, inc luding an over turn. HOW T O A VOID THE HAZA RD Never attem pt stunts, such as wheel ies or jumps. Don’ t try to show off. W ARNING[...]

30 OPERA TION W ARNINGS POTENT IAL HA ZARD Fai lure to ins pect the A TV befor e operating. Fail ure to proper ly m aintain the A TV . WHA T CA N HAPPEN Incre ase s th e p ossib ility o f an acci dent or equipm ent damage. HOW T O A VOID THE HAZA RD Alw ays ins pect your A TV each ti me you us e it to mak e sure the A TV is in s afe operati ng cond[...]

31 OPERA TION W ARNINGS POTENT IAL HA ZARD Rem oving hands from handlebar s or feet from footres ts duri ng operation. WHA T CA N HAPPEN Rem oving even one hand or foot can reduce y our ab ility to con tro l th e A TV or could c ause you to los e your balanc e and fall off the A TV . If y ou rem ove a foot from the footrest, your foot or leg m ay c[...]

32 OPERA TION W ARNINGS POTENT IAL HA ZARD Fail ure to use ext ra care w hen operating thi s A TV on un fa miliar t e rrain . WHA T CA N HAPPEN Y ou can come upon hi dden rocks, bumps, or holes, wi thout enough time to r eact. Coul d resul t in the A TV overt urning or going out of contr ol. HOW T O A VOID THE HAZA RD Go slow ly and be extr a caref[...]

33 OPERA TION W ARNINGS POTENT IAL HA ZARD Fail ure to use ext ra care w hen operating on exces sivel y rough, sli ppery or l oose terrai n. WHA T CA N HAPPEN Coul d cause los s of tract ion or vehic le c ontrol, whi ch could r esult i n an ac cident, includi ng an over turn. HOW T O A VOID THE HAZA RD Do not oper ate on excess ively rough, sl ippe[...]

34 OPERA TION W ARNINGS POTENT IAL HA ZARD T urning i mproper ly . WHA T CA N HAPPEN A TV co uld g o ou t of co nt rol, ca usin g a co llision o r overt urn . HOW T O A VOID THE HAZA RD Alw ays follow proper pr ocedures for turning as desc ribed i n the Ow ner ’ s Manual . See page 86 . Practi ce turni ng at low speeds before attem pting to turn [...]

35 OPERA TION W ARNINGS POTENT IAL HA ZARD Climbin g h ills impr operly . WHA T CA N HAPPEN Coul d cause loss of control or caus e A TV to over - turn. HOW T O A VOID THE HAZA RD Alw ays follow proper procedur es for cli mbing h ills as desc ribed i n the Owner ’ s Manual . See pages 91 through 96. Alwa ys check th e te rra in care fu lly bef ore[...]

36 OPERA TION W ARNINGS POTENT IAL HA ZARD Going dow n a hill im properl y . WHA T CA N HAPPEN Coul d cause loss of control or cause A TV to overtur n. HOW T O A VOID THE HAZA RD Alw ays follow pr oper procedures for goi ng down h ills as desc ribed i n the Owner ’ s Manual . See page 94. NOTE : A special tec hnique is requi red when br aking as [...]

37 OPERA TION W ARNINGS POTENT IAL HA ZARD Impr operly c rossi ng h ills or tu rnin g o n hills. WHA T CA N HAPPEN Coul d cause loss of contr ol or caus e A TV to overtur n. HOW T O A VOID THE HAZA RD Never attempt to tur n the A TV ar ound on any hill until you have m astered the turni ng technique as descr ibed in the Owner ’ s Manual on level [...]

38 OPERA TION W ARNINGS POTENT IAL HA ZARD Sta llin g, ro llin g b ackwa rds o r imp r operly di smount- ing wh ile climbin g a hill. WH A T CAN HAPPEN Could r esult in A TV ov erturn- ing. HOW T O A VOID THE HAZA RD Mai ntain steady s peed when cli mbing a h ill. If you l ose all for ward speed : Ke ep weig h t up hill. A p - ply t he brakes. Loc [...]

39 OPERA TION W ARNINGS POTENT IAL HA ZARD Skiddi ng or sli ding. WHA T CA N HAPPEN Y ou may l ose contr ol of the A TV . Y ou may also r egain tr action unex pectedly , w hich m ay c ause the A TV to over- turn. HOW T O A VOID THE HAZA RD On sli ppery s urfaces, s uch as ice, go sl owly and be ver y cautious in or der to reduc e the chance of sk i[...]

40 OPERA TION W ARNINGS POTENT IAL HA ZARD Impr operly oper ating over obstacl es. WHA T CA N HAPPEN Cou ld cau se lo ss of con tro l or a collision . Co u ld cau se th e A TV to ove rtu rn. HOW T O A VOID THE HAZA RD Before oper ating in a new area, check for obs tacles. Use ex trem e caution when r iding ov er lar ge obstacles, such a s lar ge ro[...]

41 OPERA TION W ARNINGS POTENT IAL HA ZARD Ri ding on froz en lakes and r iver s. WHA T CA N HAPPEN Sever e injur y or death can result if the A TV and/or the operator break through the i ce. HOW T O A VOID THE HAZA RD Never ride y our A TV on a fr ozen body of water . W ARNING[...]

42 OPERA TION W ARNINGS POTENT IAL HAZARD Operating this A TV through deep or fas t flowi ng water . WHA T CA N HAPPEN T ires m ay float, causi ng los s of tracti on and loss of control , which could lead to an acci dent. HOW T O A VOID THE HAZA RD A void operati ng the A TV t hrough deep or fast fl owing w ater . If y ou canot av oid water whic h [...]

43 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV wi th impr oper tires, or with i mproper or uneven tire pr essure. WHA T CA N HAPPEN Use of im proper ti res on this A TV , or operation of this A TV with i mproper or un- even tir e press ure, may caus e loss of control , and incr eases the ris k of an acci - dent. HOW T O A VOID THE [...]

44 OPERA TION W ARNINGS POTENT IAL HA ZARD Over loading this A TV WHA T CA N HAPPEN Coul d cause changes i n vehicl e handling w hich coul d lead to an acci dent. HOW T O A VOID THE HAZA RD Never exceed the stated load c apacity f or this A TV . Car go should be proper ly di stri buted and securel y attached. W ARNING[...]

45 OPERA TION W ARNINGS After a roll over or an acc ident, have a qualified s ervi ce dealer chec k the com- plete m achine incl uding, but not li mited to, brakes , throttle and steeri ng for possi ble damage. Safe operati on of this r ider ac tive vehi cle requi res good j udgement and physica l skills. P erso ns wit h c ognitive or physi cal dis[...]

46 OPERA TION W ARNINGS POTENT IAL HA ZARD Operati ng this A TV wit h improper modifi cations. WHA T CA N HAPPEN Impr oper ins tallation of accessor ies or modifi cation of thi s vehic le may cause changes i n handling w hich in s ome situati ons could l ead to an accident. HOW T O A VOID THE HAZA RD Never m odify this A TV through impr oper instal[...]

47 VEHICLE IDENTI FICA TION NUMBERS 2 1[...]

48 VEHICLE IDENTI FICA TION NUMBERS Recor d these number s f rom y our A TV i n the spaces provi ded. 2. Fr ame VIN ( found on the front of fr ame below steering pos t) 1. Engine Ser ial N umber ( Left side of engi ne crankc ase) Rem ove the spare k ey and store i n a safe place. Y our key can be dupli cated only by obtaini ng a key bl ank from Pol[...]

49 CONTROL AND P ARTS FUNCTIONS Engine Electr ical Switches 1 - Main Switch - Loc ated on the Ri ght-hand side of the Scram - bler s (A) and on the pod of the Sportsm an (B). This switch is operated w ith a key an d must be turned c lock- wi se to the “on” po sitio n t o sta rt the engine. A B 1[...]

50 CONTROL AND P ARTS FUNCTIONS 2 - Emerge ncy Engi ne Stop Switc h The engine will no t sta rt or run whe n th e switch is in its “ off” position. Its purpose is t o provide the operator with a qui ck means of engine shutdown i n case of stuck throttle or other emer gency . NO TE: Both the main sw itch and the emer gency engine s top swi tch s[...]

51 CONTROL AND P ARTS FUNCTIONS 3 - Engine Star t Button -T os t a r t the engine, m ake cert ain the tether swi tch is secur ely plugged i nto the machi ne and attached to the ri der ’ s ri ght wri st. T urn the key to the “on” posi tion, set the par king br ake, and push the star t button. NOTE: Remem ber to rel ease the park brak e before [...]

52 CONTROL AND P ARTS FUNCTIONS Engine or drivel ine damage c ould occur if the mac hine is dr iven w ithout the park br ake releas ed. Thi s A TV is not equipped wi th lighting. This A TV is desi gned for off- road use only and must not be r idden on str eets or hi ghways. Use cauti on and dri ve at reduc ed speeds in condi tions of r educed vis i[...]

53 CONTROL AND P ARTS FUNCTIONS Engi ne Throttle Indica tes a potential haza rd which coul d result in severe injury or d eath. Do not s tart or oper ate an A TV wi th stick ing or i mproper ly oper ating throttl e contr ols. A stuc k or im properl y operati ng throttle c ould cause an acc ident res ulting i n severe i njury or death. Alw ays conta[...]

54 CONTROL AND P ARTS FUNCTIONS Throttle Lever Engine s peed and vehicl e movem ent are con- trol led by press ing the throttl e lever . The throttl e lever ( 1) i s spri ng loaded and engine speed r eturns to idl e when the lev er is r e- leas ed. Thi s vehic le is equi pped with an El ectroni c Throttl e Control (ET C) w hich is des igned to redu[...]

55 CONTROL AND P ARTS FUNCTIONS The El ectronic Throttle C ontrol ( ETC) stops the engi ne in the event of a throttle system malfunction a nd is provide d for your safety . Do no t at- tempt to mod ify the ETC syste m or replac e it with an y after market throttle mec hanism.[...]

56 CONTROL AND P ARTS FUNCTIONS Switches Each Polar is A TV has a m ain swi tch. It is l ocated on the right hand s ide of the mac hine or headl ight pod and operated w ith a key . Indica tor Lights Each Polar is A TV has indi cator li ghts. This m odel has a low oil w arning light. When this r ed dot is lit , it is indi cating a low oi l level .[...]

57 CONTROL AND P ARTS FUNCTIONS Front an d Rear Br akes T o activ ate the rear br ake (A), squeeze the l eft hand lever to- war d the handlebar . The fr ont brakes ( B) ar e activated by squeez ing the lev er on the RH handlebar . A B Alw ays apply both brakes at the sam e time or loss of vehicl e con- trol can occur r esulting i n seri- ous inj ur[...]

58 CONTROL AND P ARTS FUNCTIONS Park in g Bra ke Setting the Par king Brake 1. Squeeze t he left hand brake l ever ( A). 2. P ush th e p ark b rake lo ck (B) down . Th is will pre- vent the l ever from returni ng to the r eleased posi tion. Alw ays check to be sure that the par king br ake has been dis engaged before operati ng the A TV . An acci d[...]

59 CONTROL AND P ARTS FUNCTIONS 3. T o releas e the parki ng brake loc k, squeeze the br ake lev er . The park ing brake will rel ease automatic ally . Im portant S afeguards NOTE: Th is veh icle ha s a P VT system wh ich is alwa ys in fo rward. Always lo ck the park brak e before start ing the engine. Alw ays lock the parking br ake whenever the v[...]

60 CONTROL AND P ARTS FUNCTIONS Gasoli ne is hi ghly fl ammabl e and explosi ve under cer tain condi tions. D Alw ays exer cise extr eme cauti on whenever handli ng gasoline. D Alw ays refuel with the engi ne stopped and outdoors or in a wel l ventil ated area. D Do not s moke or all ow open flam es or spar ks in or near the area w here re- fueli n[...]

61 CONTROL AND P ARTS FUNCTIONS Indicates a po tential hazard which could result in severe injury or death. W ARNING The engi ne exhaust fr om this prod- uct contai ns chemic als know n to cause c ancer , birth defects or other repr oductive har m.[...]

62 CONTROL AND P ARTS FUNCTIONS PV T System The PVT system rota tes at high speeds, creati ng large am ounts of force on clutc h components. Extensi ve engineeri ng and testing has been c onducted to insur e the safety of thi s product. However , as the ow ner you have the fol - low ing res ponsib ilities t o ma ke su re t his syst em rema in s saf[...]

63 CONTROL AND P ARTS FUNCTIONS Engi ne Fuel and Oil Sy stem Fuel System The fu e l tan k filler cap (1 ) is locat ed d irect ly behind the handl ebar . The tank has a ca- pacit y of 1.3 gallons (5 lit ers). Us e un- leaded gas oline wi th a mi nimum pump oc- tane number of 87 octane. 1[...]

64 CONTROL AND P ARTS FUNCTIONS The fuel valve is located on the engine, be- hind the r ight front fender and has three posi tions: OFF: For vehic le stor age and whenever transpor ting. ON: For norm al operation. RES: For r eserve s upply i n the event of mai n supply exhaus tion. NOTE: There is about a 7 to 10 mil e (1 1.2 to 16 km ) range on r e[...]

65 CONTROL AND P ARTS FUNCTIONS Engi ne Fuel Safety /Fuel/Fil ter The Pol aris A TV i s equipped wi th an in- line fuel fil ter . Thi s filter should be r eplaced by your dealer after every 100 hour s of operati on or annuall y . Do not attem pt to clean the fuel fil ter . Use onl y Polari s injecti on oil. Never subs titute or mix oi l brands. Ser[...]

66 CONTROL AND P ARTS FUNCTIONS Oil System The oi l tank (1) is loc ated under the seat and has a capaci ty of 12 ounces (1 l iter) . T o re mo ve th e se a t, reac h under the rear of the cab and pull back on the seat l atch. T o re- place the s eat, set it in plac e and push down on the rear of seat. Alway s make sure the sea t is lock ed in plac[...]

67 CONTROL AND P ARTS FUNCTIONS Pol aris 2 - Cycl e Lubricants Polar is has a fami ly of premi um oil s availabl e for use in all our products and hi ghly recom mends their use. The only oils r eco mmended for Polar is 2- cycle A TVs are Po- laris Pre mium 2 -cycle o il or P remium G old S ynth et ic 2-cycle oil. Engine w arranty cover age may bec [...]

68 CONTROL AND P ARTS FUNCTIONS Pola ris Premium 2-cycle lubricant s are the most ad van ced fo rmulatio n of oils spe - cifical ly designed for today ’ s 2-cycle engines. Months of lab and field tests have resul ted in a new gener ation o f 2-cycle lubr icants. Pola ri s Prem ium 2-cycle l ubri- cants provide additi ves for 2-cycle engi nes lack[...]

69 CONTROL AND P ARTS FUNCTIONS Kick Star ter If the battery is w eak and cannot start the en- gine , kick st art le ver will a llow v eh icle opera- tion unti l repai rs can be m ade. 1. Be certai n your vehicl e is on a level surface and the park ing brake i s set. See page 58. 2. Fo ld ou t th e kick st art le ver (A) wh ich is o n th e left han[...]

70 ST ARTING THE ENGINE Pr ocedur e for Star ting a Cold E ngine Indica tes a potential haza rd which could result in severe injury or d eath. Nev er run an engi ne in an enclos ed area. Car bon monoxi de exhaust gas i s poi- sonous and can cause sev ere injur y or death. Alway s start engi nes outdoors. Y ou must all ow your vehi cle adequate war [...]

71 ST ARTING THE ENGINE 1. Set the par king br ake. 2. T urn the fuel tank valve to O N. 3. Si t on the vehicl e. 4. Attach tether strap to m achine and wr ist. 5. T urn the engi ne stop swi tch to RUN. 6. T urn the i gnition key t o ON. 7. Pr ess the star ter button. NOTE: The rear brak e lever mus t be engaged or the en- gin e will n ot st art . [...]

72 RIDING GEAR Safe R iding Gear Alw ays wear cl othing suited to the ty pe of ridi ng you are doi ng. A TV ri ding requi res spec ial pr otective cloth in g which will make yo u fe el more co mfo rta ble and reduc e chances of i njury . 1. Helmet Y our hel met is the m ost im portant piece of pr otec- tive gear for safe r iding. A helmet c an prev[...]

73 RIDING GEAR 2. Eye Prot ection Do not depend on sunglass es for proper eye protect ion. A pair of goggles or hel- met f ace shiel d offer the best protecti on for your eyes. They should be k ept clean and be of shatter proof desi gn (beari ng the mark ings z2.1 or VESC 8) . 3. Gloves Of f-road st yle glov es with k nuckle pads are the bes t for [...]

74 VEHICLE BREAK- IN PERIOD 2 - Cycle E ngines The br eak in peri od for your new Polar is A TV is defi ned as the tim e it takes to use the fir st tank of gas oline. No singl e action on y our part i s as im portant as a pr oper break i n period. Careful tr eatment of a new engine will resu lt in mo re efficie nt p e r- form ance and longer li fe [...]

75 VEHICLE BREAK- IN PERIOD 3. D rive s lowly at fi rst. Select an ar ea whic h is open and will give you ro om t o fa miliar- ize y oursel f with v ehicle oper ation and handli ng. 4. V ary the thr ottle positi ons. 5. Per form r egular c hecks on fl uid level s, contr ols and all impor tant areas on the ve- hicl e as outli ned earli er on the dai[...]

76 VEHICLE BREAK- IN PERIOD After the br eak in per iod the oil inj ecti on syst em provi des the necessa ry engi ne lubr ication w ithout the need for pre- mix ed fuel. After the fi rst tank of pre-m ixed fuel has been used pl ease ver ify that the oi l level in the oi l tank has dr opped, indic ating that the oil pump i s functioni ng properl y .[...]

77 CARR YING LOADS The Spor tsman 90 has been des igned to carr y a cer tain amount of l oad. CARGO WEIGH T should be ev enly dis tributed ( 1/3 on the front and 2/3 on the rear ) and mounted as low as possibl e. When oper ating over r ough or h illy terra in , r educe speed and car go to maintai n stable dr iving c onditions. Never exceed the wei [...]

78 CARR YING LOADS 2/3 of Load on Rear Rack 1/3 of Load on Front Rack Im portant S afeguards T o reduce risk of i njury or machine damage when carrying loads, read and follow the w arnings listed below : D REDUCE SPEED AND ALLOW G REA TER DI ST ANCE F OR BRAKING WHEN CARRYING CARGO. D CARG O WEIGHT DISTRIB UTION should be 1/3 on the front rack and [...]

79 CARR YING LOADS D HEA VY LOADS CAN CAUSE BRAKI NG AND C ONT ROL PROBL EMS. Use extreme caution when appl ying brakes with a loaded vehicl e. A void terrain or situations which may requir e backing downhill. D ALL L OADS MUST BE SECURED BEFORE M OVING VEHICL E. Unse - cured loads can create unstable operati ng conditions, which could result in lo[...]

80 CARR YING LOADS D EX T REME CAUTION MUS T BE USE D when operating wi th loads extend - ing over the r ack sides. Stability and maneuverability may be adversely af fected, causing the machine to overturn. D DO NOT T RA VEL F AST ER T HAN TH E RECOMM ENDED SPEEDS.[...]

81 DAIL Y PRE - RIDE CHECK Y ou mus t inspect y our A TV each tim e before ri ding to ensure it i s in proper wor king order . If proper c heck is not done, sever e inj ury or death could res ult.[...]

82 DAIL Y PRE - RIDE CHECK Use t he follow ing checkl ist t o verify your mac hine is in pr oper wor king or der each tim e you ride. Item/In spection Pr ocedure 1. T ir es - check condi tion and pressur es 2. Fuel and oil tank s - fill both tanks to their proper l evels 3. Al l brakes - chec k operation and adjustm ent. 4. Thr ottle - c heck for f[...]

83 DAIL Y PRE - RIDE CHECK 8. D rive c hain - condi tion and sl ack; refer to driv e chain adjus tment 9. Ai r cleaner elem ent - check for dir t; clean or repl ace 10. Steeri ng - chec k for fr ee operation noti ng any unusual l ooseness in any area 1 1. Loose parts - visual ly inspec t vehi cle for any damaged or l oose nuts/bol ts or fas - tener[...]

84 RIDING[...]

85 RIDING 1. Si t upright w ith both feet on the footr ests and both hands on the handl ebars. 2. Star t the engine and all ow it t o warm up. 3. C heck your sur roundings and deter mine y our path of tr avel. 4. R elease the par king brak e. 5. Sl owly depr ess the thr ottle with y our right thumb and begin driv ing. V ehicl e speed is c ontroll e[...]

86 RIDING Making T urns[...]

87 RIDING Pr actice making turns at slow sp eeds. Polar is A TVs ar e equipped wit h a solid r ear axl e whic h drives both rear wheels equall y at all tim es. Thi s means that the w heel on the outsi de of the turn mus t trav el a greater dis tance than the insi de wheel w hen turning and the inside ti re must sl ip tracti on slightl y . T o turn,[...]

88 RIDING Riding On Slippery Sur faces Wh enever ridi ng on slipp ery surfaces su ch as wet trails or loose g ravel, or du r - ing cold f reezing weat her , special at tent ion mu st be paid t o preven t vehicle tu rnover . Always:[...]

89 RIDING 1. Sl ow down when enter ing sl ippery areas . 2. M aintain a hi gh level of al ertness , reading the trai l and avoidi ng quic k, sharp tur ns whi ch can cause s kids. 3. C orrect a ski d by tur ning the handlebar s in the direct ion of t he skid and shifting your body wei ght forwar d. 4. N ever apply brak es during a s kid. Complete l [...]

90 RIDING T raveling Uphill 15 _ Maximum[...]

91 RIDING If you h ave to travel up hill always travel st raight uphill and: 1. Avo id ste e p hills (1 5 _ ma ximu m). 2. Keep both feet on the footr ests. 3. T rans fer your weight forw ard. 4. Pr oceed at a steady r ate of speed and throttl e opening. 5. R emain al ert and be prepared to take emer gency action. T his may inc lude quick dism ount[...]

92 RIDING Sidehilling[...]

93 RIDING A void t raveling acro ss the side o f a hill at all costs. In the even t you do enter into a situ ation where sidehillin g is unavoidab le, a lways: 1. Sl ow down. 2. Lean i nto the hill tr ansferr ing your upper body wei ght up hill while k eeping your feet on the footres ts. 3. Steer sli ghtly i nto the hill to m aintain vehi cle dir e[...]

94 RIDING T raveling Downhill[...]

95 RIDING Whenever descend ing a h ill, always: 1. Drive dire ctly d o wnh ill. 2. T ransfer y our weight to the rear of the vehicl e. 3. Sl ow down. 4. Appl y the the front and rear brakes at the s ame tim e and very sli ghtly to ai d in s low- ing. Do not tr avel at ex cessi ve speeds. It is danger ous and can cause l oss of v e- hicl e control a[...]

96 RIDING T urni ng Around On A Hill 8’ Uphil l If t he A TV stalls while climbi ng a hill, never back it down the hill! One maneuver which can be used wh en it is necessary to tur n ar ound whil e c limbi ng a hil l is the K-turn.[...]

97 RIDING 1. Stop and l ock the parki ng brake w hile m aintaini ng body weight uph ill. 2. Shut of f engine. 3. D ismount on l eft or uphill side of A TV . 4. Stayi ng uphill of A TV , turn handl ebars full left (w hile faci ng front of A TV). 5. W hile hol ding serv ice br ake, rel ease parki ng brake lock and slow ly al low A TV to rol l around [...]

98 RIDING Crossing Str eams Y our Polari s A TV ca n opera te through wate r up to depths j ust below the foot- rests. Befo re for ding st reams always:[...]

99 RIDING 1. D etermine w ater depths and c urrent. 2. C hoose a cros sing wher e both banks have gr adual inc lines. 3. Pr oceed slow ly , avoiding r ocks and obs tacles i f possi ble. 4. After cross ing, dry the brakes by apply ing light pres sure to the lever s until br aking action i s normal . If you do not perfor m this proc edure, your br ak[...]

100 RIDING T rail Obstacles[...]

101 RIDING Keep A lert! Look ahead and lear n to read the tr ail as you r ide. Stay on the ri ght side of the trai l, if poss ible, and be cons tantly aler t for hazar ds such as logs , rocks and l ow hanging br anches. Not all ob st acle s are visib le. T rave l with ca ut ion o n tra ils. sev ere in jury or death can r esult if your mac hine come[...]

102 RIDING P a r k i n go na nI n c l i n e[...]

103 RIDING Wh enever th e V ehicle is Parked 1. T urn the engi ne off. 2. Set the par king br ake. 3. A void par king on an incli ne. If it is necess ary to park on an incl ine, al ways block the rear wheels on the dow n hill side as s hown above. 4. Shut of f fuel suppl y .[...]

104 PVT SYSTEM OPERA TIO N PV T System The PVT system rota tes at high speeds, creati ng large am ounts of force on clutc h components. Extensi ve engineeri ng and testing has been c onducted to insur e the safety of thi s product. However , as the owner y ou have the follow - ing r esponsib ilities to ma ke sure t his syst em re main s sa fe: D Do[...]

105 PVT SYSTEM OPERA TIO N If the vehi cle is operated i n dusty areas , it will be ne cessa ry to cle an t he f ilte r more often. T o clean the PVT filter: 1. Remove th e screws and the cran kcase cove r . 2. R emove the scr ews and the fi lter c over . 3. Soak the f ilter in a m ild deter gent and rins e with c lean water . 4. Al low the fil ter[...]

106 BA TTERY Batter y Only adul ts should ev er touch the batter y . Never allow childr en to handle a battery or s ervic e a battery in any way . Whenev er rem oving the batter y , disconnec t the negative ( black) cable first. Whe n re inst allin g th e b at te ry , c onnect the negativ e (blac k) cabl e last or an ex plosiv e situati on could re[...]

107 BA TTERY Battery el ectrol yte is poisonous . It contains sul furic aci d. Serious bur ns can res ult from contact wi th skin, eyes or clothi ng. Antidote: External: F lush wi th water . Internal: D rink l arge quantiti es of water or mi lk. Foll ow with m ilk of mag- nesia, beaten egg, or vegetable oi l. Call phy sici an imm ediately . Eyes: F[...]

108 BA TTERY Reple nis hing the Batte ry Fluid A poorly m aintained battery will dete rio rat e ra p idly . Check the battery flui d level often. The fl uid level should be k ept between the upper and l ower l evel mark s. T o re fill use o n ly distille d wat er . T ap wat e r cont ain s mi nerals whi ch are harm ful to a battery . Maintain betwee[...]

109 BA TTERY Batt ery Remova l 1. D isconnect hold dow n straps hol ding the elect rical box and battery i n positi on. 2. D isconnect the bl ack (negativ e) battery cabl e firs t. 3. D isconnect the red ( positi ve) batter y cable nex t. 4. Li ft the battery out of the A TV , being car eful not to tip it sidew ays and s pill electro- lyte. If ele [...]

11 0 BA TTERY Battery In stallation and Conn ections Battery term inals and connecti ons should be k ept free of cor rosion. If cl eaning is nec essary , rem ove the cor rosion w ith a sti ff w ire br ush. W ash with a soluti on of one tablespoon bak ing soda and one cup w ater . Ri nse well with tap water and dry of f with c lean rags . Coat the t[...]

111 BA TTERY 1. Set the battery i n its holder . 2. Fi rst c onnect and tighten the r ed (posit ive) c able. 3. Second c onnect and tighten the blac k (negati ve) cabl e. 4. Attach the hol d down str ap. 5. V erify that cabl es are proper ly routed. NOTE: D When y our A TV i s placed i n storage for t hree months or more, t he battery should be r e[...]

11 2 NOISE EMISSION CONTROL SYSTEM REG ULA TI ON T AMPERING WIT H NOISE CONTROL SYSTEM PROH IBITED! U.S. F ederal l aw prohi bits the fol lowing ac ts or the c ausing thereof: (1) The rem oval or r endering i noperativ e by any pers on other than for pur poses of mai ntenance, repai r , or r eplacement of any device or el ement of desi gn incorpo- [...]

11 3 NOISE EMISSION CONTROL SYSTEM REG ULA TI ON 2. Rem oval or alterati on or the puncturi ng of any par t of the engine air i nduc tion sys- tem. 3. R eplacement of any vehi cle parts wi th parts not in compli ance wi th federal regula- tions. 4. Lack of proper m aintenance. CAUTION: Remember , exhaust syst em components are ver y hot duri ng and[...]

11 4 NOISE EMISSION CONTROL SYSTEM REG ULA TI ON USF S Appr oved Spark Arr estor Mos t Polari s A TVs hav e muffl ers that wer e tested and approv ed in accor dance wi th the USFS F orest Ser vice Standar d 5100-1A.[...]

11 5 MAINTENANCE T ool Kits T o help you per form routi ne maintenanc e, a tool ki t is pr ovided in the stor age compar tment under the seat. Items inc luded in the ki ts are: 2 -cycle engines D spa rk plug wre n ch with P hillip s head scr ewdri ver D tir e pressur e gauge Pe riodic Mai ntenance Sc hedule Car eful periodi c maintenance will help [...]

11 6 MAINTENANCE Mai ntenance inter vals ar e based upon average r iding c onditions and an av erage vehic le speed of appr oxim ately 10 mi les per hour . V ehicl es subjec ted to sever e use, suc h as operati on in wet or dusty areas, shoul d be inspected and ser vic ed mor e frequently . If you ar e not fam iliar with saf e service a nd a dju st[...]

11 7 MAINTENANCE " More ofte n under severe use, such as dirty o r wet c onditions Item Hours or Miles When Remarks Brak e Sys tem Pre-rid e Pre-ride Pre-r ide inspect ion it em Ti r e s Pre-ri de Pre-ride Inspect daily , pre-r ide inspect ion it em Wheels Pre-ride Pre-ri de Pr e-ride ins pect ion item Fr ame nut s, bolts, fas tener s Pre-rid [...]

11 8 MAINTENANCE Pe riodic Mai ntenance Sc hedule (Cont.) " More ofte n under severe use, such as dirty o r wet c onditions Item Hours or Miles When Remarks Oil P ump Cable 50 hrs 6 mont hs Inspec t, adjus t, lubr icat e, replace if re- quired Carburet or F loat Bowl 50 hrs 6 months Drain bowl periodic ally and prior to s tor age Due to the na[...]

11 9 MAINTENANCE Item Hours or Miles When Remarks J Thr ott le Cable/ ETC S witc h 50 hrs 6 mont hs Inspec t- adjust , lubricat e, replac e if neces- sary ; pr e-ride ins pect ion item " Steer ing 50 hrs 6 mont hs Ins pect daily , lubr icat e " Rear Axle 50 hrs 6 mont hs Inspec t bear ings, Lube " Fr ont Suspens ion 50 hrs 6 mont hs [...]

120 MAINTENANCE " More ofte n under severe use, such as dirty o r wet c onditions Item Hours or Miles When Remarks Engine Mount s 100 hrs 12 months Ins pect Spark P lug 100 hrs 12 months Ins pect - - replace if necess ary J Ignit ion Timing 100 hrs 12 months Ins pect and adjust as needed Due to the natur e of the adjustm ents mar ked wit h a J[...]

121 MAINTENANCE Item Hours or Miles When Remarks J Fuel S yst em 100 hours 12 mont hs Check for leaks at tank c ap, lines, f uel valve, filt er, pump and carbur etor. Re- place lines ev ery t wo year s. J Fuel F ilter 100 hrs 12 months Replace annually Spark arres tor 100 hrs 12 months Clean out J Fr ont wheel bear - ings 300 hrs 36 months Ins pect[...]

122 MAINTENANCE Lubrica tion Rec ommendati ons Item Lube R ec . Method Fre quency * 1. Engine O il Pola ris Inject ion O il Fill oil t ank. S ee page 63. As needed, when refueling 2. Transmiss ion Oil Pola ris Premium Synt hetic gear case lu be See Page 146 Change annually or at 100 hours[...]

123 MAINTENANCE Lubri cation Rec omme ndations Operati ng Range 2. T ransm issi on (pl ug)[...]

124 MAINTENANCE 3. Driv e Chain O- Ring chain lube or SAE 80/ 90 Lubr icat e as of ten as re- quired. Bef ore eac h ride in wet condit ions As requir ed 4. Fr ont A-A rm L Gr ease ** Locat e fit ti ngs and greas e Every 3 mont hs or 50 hours L Mor e often under sever e use, such as wet or dusty conditi ons. **Pol aris Pr emium all Season Gr ease or[...]

125 MAINTENANCE NOTE: Hours ar e based on 10 mph av erage. 4.[...]

126 MAINTENANCE Period ic Maint enance R ecord Use t he follow ing chart t o recor d periodi c maintenanc e work: Maintenance In terval Perfo rmed Ser vic ing Date Ser vic ing Dealer or Pe rson Remarks Firs t 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.[...]

127 MAINTENANCE Maintenance In terval Perfo rmed Ser vic ing Date Ser vic ing Dealer or Pe rson Remarks[...]

128 MAINTENANCE Hand lebar Ad justment Y our A TV has handl ebars whi ch can be adjus ted for your personal fi t. 1. Locate handl ebar bolts . On models with a headlight pod, it will be n ece ssary t o rem ove the upper “headl ight” pod. On other models rem ove the handlebar cover . Impr oper adjustm ent of the handlebars or incor rect torqui n[...]

129 MAINTENANCE 2. Loosen the four bolts. 3. Adj ust handlebar to des ired hei ght. Be sur e handlebars do not hi t gas tank or any other part of machi ne when turned ful ly to left or right. 4. T orque handlebar adjuster bl ock bol ts to 7.3 ft. lbs. NOTE: T ighten bolts so ther e is an equal gap at the front and r ear of the handlebar bl ock. Imp[...]

130 MAINTENANCE The fol lowi ng items s hould be checked oc casional ly for tightnes s; or i f they have been loosened for maintenanc e servi ce. Axle and Wheel Nut T orque Specification s Sp ecif icat io n Fr ont S pindle Nuts 43 ft. lb s Rear Spindle Nut s 80 ft. lb s. NOT E: All n uts th at have a cot ter pin installed mu st be serviced by an au[...]

131 MAINTENANCE Rear Spr ing Adju stment The rear shoc k absorber spr ing is ad- just ed by rotating the adj uster i n the dir ection r equired to i ncreas e or decr ease spr ing tension. Rear Spr ing Adjust ment Cam[...]

132 MAINTENANCE Air Cleaner Inspect the filter w eekly or after every 50 hours of oper ation. If the vehicle i s rid- den in w et or dusty c onditions, c lean the fil ter mor e often. Never operate the A TV wi th the filter element r emoved. Dir t will en t er t he engine caus ing ser ious rapi d wear and dam age to the engine.[...]

133 MAINTENANCE T o clean the filter: 1. Remove the screws o n the airbox (A) and re- move t h e filt er (B). 2. Soak the f ilter in a m ild detergent and r inse i t i n clean w ater . 3. Let the filter ai r dry and rei nstall in the air box. A B[...]

134 MAINTENANCE Steering Inspection The steer ing assem bly of the m achine s hould be checked per iodic ally for loose nuts and bolts . If loose nuts and bolts are found, have your dealer ti ghten them before r iding y our vehic le. Camber and Caster The cam ber and cas ter are non- adjustabl e. Do not attem pt to adjust the tie r od for toe ali g[...]

135 MAINTENANCE Throttle S top System This vehicle is equipped with a throttle stop system that controls how far the throttle opens. Using this feature, adults can limit how fast the machine will tra vel. T o adjust, loosen the jam nut (D) T urn the screw (E) inw ard to re - duce speed and outward to in- crease speed. Ti ghten jam nut after adjusti[...]

136 MAINTENANCE T oe Ali gnment Y ou can check the toe alignment of the vehicle using the foll owing method. The recommended toe alignment is 1/8 ″ to 1/4 ″ ( . 3t o. 6c m )t o eo u t . I fy o u discover improper adjustment have your dealer correct it. 1. Set the handlebars in a strai ght ahead position and hold them in this position. NOTE: The[...]

137 MAINTENANCE T oe Alignm ent (cont.) 2. Pl ace stands in front of the machine, perpendicular to the rear tires. 3. T ie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of m achine and goes around the stands in front of the machine. 4. Measure from string to ri m at front and rear o[...]

138 MAINTENANCE Brake A dju stment Periodi cally check the freeplay of the front and rear brakes. R efer to the chart below for the acceptable range of free- play for your machi ne. T o adjust the front brake, turn the adj ust - ment knob (A) until the freeplay is accept- able. A[...]

139 MAINTENANCE T o adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is at- tained. B[...]

140 MAINTENANCE Brake Fr eeplay Adjustment Model Front Rear Sportsman 90 .39 ″ -. 7 8 ″ 10 mm - 20 mm .39 ″ -. 7 8 ″ 10 mm - 20 mm Scrambl er 90 .39 ″ -. 7 8 ″ 10 mm - 20 mm .39 ″ -. 7 8 ″ 10 mm - 20 mm Scrambl er 50 .1 ″ -. 3 9 ″ 2.5mm - 9.9 mm .15 ″ -. 3 0 ″ 3.8mm - 7.6mm[...]

141 MAINTENANCE Throttl e Cable Adj ustment Always check the throttle for smooth operation before riding. Periodi cally check the throttle freeplay . It should be kept bet- ween 1/16 ″ and 1/8 ″ (1.5mm - 3.2mm) (C). If adjustment is re- quired, turn the adjustment nut (D) until the freeplay falls in to the ac- ceptable limit. Indica tes a poten[...]

142 MAINTENANCE Spa rk Pl ugs The spar k plug requi red for this m achine i s NGK BP7HS or NGK BPR7H S. Incor- rec t spark pl ug gap can cause the s park plugs to foul. The spar k plug gap shoul d be between 0.6 - 0.7 mm. The spar k plug and i ts conditi on is indi cative of engine oper ation. The spar k plug fir ing end conditi on should be r ead [...]

143 MAINTENANCE 2. Wet Fouled The i nsulator ti p is blac k. A damp oi l film covers the fir ing end. Ther e may be a car bon layer ov er the entir e nose. General ly , the electr odes are not w orn. Gener- al c auses are ex cessiv e oil, us e of non-rec ommended i njecti on oil, i mpr oper use of the choke, or incorr ect carbur etion adjustm ents.[...]

144 MAINTENANCE Spark Plug Rem o val and Replacement The spar k plug i s rem oved by usi ng the special wrench pr ovided i n the tool pouch. Rem ove the spark plug cap and then the s park plug by rotating counter clock wise. Rever se the proc edure for s park plug i nstallati on. T orque to 17 ft. lbs . Never deviate fr om the recom mended spar k p[...]

145 MAINTENANCE Cylind er Head/Cylin der Base Fast ener T orque (2- Cycle Mod els) Hav e your dealer check the A TV cy linder head and cyl inder bas e fasteners for proper torque at the fir st ser vice or after 25 hour s. Indica tes a potential haza rd which could result in severe injury or d eath.[...]

146 MAINTENANCE T ra nsmiss ion Lubric ation The transm issi on dipstic k (A) is l ocated on the top of the tr ansmis sion. The tr ansmi ssion l ubric ant level shoul d be check ed monthly . T ransm issi on oil s hould be changed annual ly . With the A TV on a level s urface, rem ove fill pl ug dipstic k and check the lubric ant level . Lubricant s[...]

147 MAINTENANCE T ra nsmiss ion Oil C hanging Pr ocedur e 1. R emove fill pl ug/dipstick . 2. R emove trans mis sion drai n plug and dr ain the oi l. Catch and dis card used oi l pr op- erl y . 3. C lean and rei nstall the drai n plug. 4. Add Polar is Premi um Synthetic Gearcase Lubri cant (PN 2871478 - 12 oz. bottle) to full mar k on the fill plug[...]

148 MAINTENANCE Operati ng your A TV wi th worn ti res, i mproper ly infl ated tires , non-standar d tires or impr operly i nstall ed tires will affect ve hicle handli ng whic h could caus e an acci dent result ing in seri ous injur y or death. Foll ow the safeguar ds li sted below to pr event this ty pe of situati on.[...]

149 MAINTENANCE Im portant S afeguards Mai ntain proper tir e pressur e accordi ng to charts below . Improper tire inflati on may af fect A TV maneuv erab ility . Do not us e impr oper tir es. The use of non-standar d s ize or type tir es m ay af fect A TV handli ng. Mak e certai n the wheel s are i nstall ed proper ly . If wheels are i mpr operly [...]

150 MAINTENANCE Wh eel Size PSI Wh eel Nut T orque Scra mb ler 5 0 Fron t 16 x 8 - 7 2 22 ft. lbs Rear 16 x 8 - 7 2 22 ft. lbs Scra mb ler 9 0 Fron t 18 x 7 - 7 2 22 ft. lbs Rear 18 x 7 - 7 2 22 ft. lbs Sports man 90 Fr ont 19 x 7 - 8 2 22 ft. lbs Rear 18 x 9.5 - 8 2 22 ft. lbs[...]

151 MAINTENANCE Wheel Installation 1. W ith the park brak e locked, place the wheel in the corr ect position on the wheel hub. Be sure the valv e stem is toward the outside and rotation ar rows on the ti re point tow ard forw ard rotati on. 2. Attach the wheel nuts and finger tight- en them. 3. Low er the vehic le to the gr ound. 4. Secur ely tight[...]

152 MAINTENANCE Tir e Insp ection When r eplaci ng a tire al ways us e origi nal equip- ment s ize and type. Tir e T read Depth Alw ays repl ace tir es when tread depth i s wor n to 1/8 ″ (.3 cm) (1 ) or l es s. 1[...]

153 MAINTENANCE Drive C h ain Inspectio n and Ad justment Polar is A TV dri ve chains are equi pped with O -ri ng sealed perm anently gr eased pins and rol lers . However , it is sti ll necess ary to lubri cate the outer surfac es of the rolle r . Regul arly l ubric ate the driv e chain w ith SAE 80-90 l ube or an approv ed O-ri ng chai n spray lub[...]

154 MAINTENANCE Drive C h ain Inspectio n and Ad justment (Cont.) The adj uster stud m ust be held sec ure when ti ghtening jam nuts or the stud may b re ak .[...]

155 MAINTENANCE Rear D rive Chain Slack Adjustment The n orma l chai n slack shoul d be kept between .40 ″ - .80 ″〈 10-20 m m) (A). Nev er adjust or operate the vehi cle w ith the rear driv e chain too l oose or too tight as sever e damage to the tr ansmis sion and dri ve com ponents can resul t. 1 A[...]

156 MAINTENANCE Adjus tment P rocedur e 1. Loosen 4 r ear housing m ount bolts (A ). 2. T ighten chai n adjuster ( B) to reduce slac k to recom mended setti ng. (.4 ″ -. 8 ″ /1 0m m-2 0m m ) 3. T ighten j am nuts on chai n adjuster . 4. T ighten the four rear housing m ount bolts. A B[...]

157 MAINTENANCE Brakelig ht Lamp Rep lacement If the brak elight does not wor k the lam p may need to be repl aced. 1. Fr om the rear of the brake l ight remov e two scr ews ( A) holdi ng lens c over in place and rem ove lens co ver (B). 2. R emove lam p (C ) and replac e it with r ecom- mended l amp. 3. T est the brakeli ght to see that it’ s wo[...]

158 MAINTENANCE Cleaning Y our A TV Keeping your A TV clean will n ot on ly impro ve its appearance but i t can als o ex- tend the li fe of vari ous components . With a few precautions , your A TV can be cleaned m uch li ke an automobi le. W ashing If a high pressu re type car wash system is used, extreme care must be take n to avoid w ater dam age[...]

159 MAINTENANCE The best and safest way t o clean your A TV is w ith a garden hos e and a pail of mi ld soap and water . Use a profess ional ty pe washing m itten, cleani ng the upper body fir st and the low er parts last. Ri nse with w ater frequentl y and dry wi th a cham ois to prevent water s pots. NOTE : If warni ng labels ar e damaged, contac[...]

160 MAINTENANCE T rans porting Whenev er the A TV i s to be transpor ted the follow ing measur es shoul d be taken. 1 . T u r nt h ef u e lv a l v et oo f f . 2. Be cer tain the fuel cap, oi l cap, and seat are i nstall ed correc tly . 3. Al ways tie t he frame of the A TV to the transpor ting unit secur ely using sui table str aps or rope. 4. Al w[...]

161 MAINTENANCE Car buretor A djustm ents If the vehi cle is to be operated at vari ous alti tudes and temper atures, cer tain ad- just ments can be m ade to impr ove its oper ation and dri veab ilit y . A b ove 6000 feet (1800 m ) the engine ai r/fuel m ixtur e becomes over ly ri ch. An engine l oses approx imately 3% of its pow er for each 1000 f[...]

162 SPECIF ICA TIO NS Specif ications - Scramb ler 50 Ri der Capacit y 1 Di splacem ent 49cc Coo ling Fan Cooled Engine type 2-Str oke Lubri cation Oil Inj ected Oil Capaci ty 1.1 quarts (1 l iter) Fuel C apacity 1.3 gall ons (5 li ters) Starti ng E lectric with kick-start ba ckup T ransm issi on Automatic C VT Fr ont Suspension A-Ar m with 2 ″ ([...]

163 SPECIF ICA TIO NS Specif ications - Scramb ler 50 Fr ont/Rear Brakes Drum Pa rkin g Bra ke Mec hanical Lock Fr ont and Rear T ires / PSI 16 x 8- 7 (2psi) T urning R adius 74.8 ″ (190 c m) Wheel Bas e 35.4 ″ (90 cm) Dr y W eight 21 1.6 lbs ( 96 kgs) Length 54.6 ″ (138.7 cm ) Widt h 34 ″ (86.3 cm ) Heig ht 34.7 ″ (88.2 cm) Brak e Light [...]

164 SPECIF ICA TIO NS Specif ications - Scramb ler 90 Ri der Capacit y 1 Di splacem ent 89cc Coo ling Fan Cooled Engine type 2-Str oke Lubri cation Oil Inj ected Oil Capaci ty 1.1 quarts (1 l iter) Fuel C apacity 1.3 gall ons (5 li ters) Starti ng E lectric with kick-start ba ckup T ransm issi on Automatic C VT Fr ont Suspension A-a rm with 2 ″ ([...]

165 SPECIF ICA TIO NS Specif ications - Scramb ler 90 Fr ont/Rear Brakes Drum Pa rkin g Bra ke Mec hanical Lock Fr ont and Rear T ires / PSI 18 x 7 - 7 (2ps i) T urning R adius 98.4 ″ (250 c m) Wheel Bas e 35.4 ″ (90 cm) Dr y W eight 233.7 lbs ( 106 kgs) Length 56.1 ″ (142.4 cm ) Widt h 34 ″ (86.3 cm ) Heig ht 36.1 ″ (91.8 cm) Brak e Ligh[...]

166 SPECIF ICA TIO NS Specif ications - Spor tsman 90 Ri der Capacit y 1 Di splacem ent 89cc Coo ling Fan Cooled Engine type 2-Str oke Lubri cation Oil Inj ected Oil C apacity 1 . 1q t s . ( 1l t r ) Fuel C apacity 1.3 ga. (5 l tr) Starti ng E lectric with kick-start ba ckup T ransm issi on Automatic C VT Fr ont Suspension A - a r mw i t h2i n/5c m[...]

167 SPECIF ICA TIO NS Specif ications - Spor tsman 90 Fr ont/Rear Brakes Drum Pa rkin g Bra ke Mec hanical Lock Fr ont T ires / PSI 19 x 7 - 8 (2 ps i) Rear T ir es / PSI 18 x 9.5 - 8 (2 psi ) Wheel Bas e 37.8 ″ (96 cm) T urning R adius 98.4 ″ (250 c m) Dr y W eight 238.1 lbs ( 108 kgs) Length 57.6 ″ (146.3 c m) Widt h 34.4 ″ (87.4 cm ) Hei[...]

168 SPECIF ICA TIO NS Specif ications - Spor tsman 90 Low Oil Li ght Standard Fr ont Rack Capac ity 10 lb (4.5 kgs) Rear R ack Capaci ty 20 lb (9 kgs) Accesso ries Ther e are a wi de range of Polar is Acc essori es avail able for A TVs. Contact y our Polar is dealer to find out about the acc essori es avail able for y our machi ne.[...]

169 WIRING DIAGRAM[...]

170 WIRING DIAGRAM[...]

171 TROUBLESHOOTING Pr ocedur es The fol lowing i nformati on is pr ovided to help y ou identify probabl e causes for questions you may have about the operati on of your A TV . See your Polar is deal er wi th any additional questi ons you may have. ENGI NE CRANK S BUT F A IL S TO ST ART No F uel W ater in F uel Spar k Plug Fuel V alve Of f Dr ain S[...]

172 TROUBLESHOOTING ENGINE ST OPS OR LOSES POWER No F uel Contact Y our Deal er Contact Y our Deal er Spark Pl ug Foul ed Engine Overheated Cl ean Engine Exteri or T urn Fuel V a l v et o“ R e s ” W ater in Fuel Air Filt er Cl ogged Electr onic Thro tt le Con tro l Mal function Fuel V ent Line Ki nked or Plugged Cl ean Radiator scr een and Radi[...]

173 W ARRANTY LIM ITED W ARRANT Y Polar is Industr ies Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMIT ED W ARRAN TY on all components of the Polar is Al l T errai n V ehicle (A TV) against defec ts in materi al or workm anship. Polaris al so gives a one year lim ited war - ranty o n the final drive c hain for failur e due to defec[...]

174 W ARRANTY REGISTRA T ION At the tim e of sale, the W arranty Regist ration Form must be completed by your dealer an d sub mitte d to Pola ris within t en days. Up on re ce ipt of this registra tio n, P ola ris will reco rd th e reg istra tio n fo r warran ty . THE P URCH ASER MUST C OMPLETE AN A TV SA FETY TRA INI NG COURS E PRO VIDE D BY THE D[...]

175 W ARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIM IT A TIONS OF W ARRANTIES AND REM EDIES The Pol aris l imi ted war ranty excl udes any failur es that are not caused by a defect in mater ial or wor kmans hip. This war ranty does not cover acci dental damage, nor mal wear and tear , abuse or impr oper handling. This w arranty als o does not cov[...]

176 W ARRANTY Thi s warr anty does not cover the use of unauthoriz ed lubri cants, chemi cals , or fuels that are not compatibl e with the A TV . T he excl usive r emedy for br each of thi s w arr an- ty shal l be, at Polari s’ exc lusiv e option, repair or r eplacem ent of any defective m ateri- als, or components or pr oducts. THE REM EDIES SET[...]

177 W ARRANTY AL L I MPL IE D W A RRANTI ES (I NCLUDI NG BUT NO T LI MITE D TO THE I MPL IE D W A RRANTI ES O F MERCHANT A BI LITY A ND FITNE SS FOR A P ARTICULA R P UR- POS E) A RE L IMITE D IN DURA TIO N TO THE ABO VE S IX MONTH W ARRANTY P E- RIOD. POLARIS FU RT HER DISCLAIMS ALL EXPRESS W ARRAN TIES N OT ST A TED IN THIS W ARR ANTY . Some state[...]

178 W ARRANTY Please w ork w ith your dealer to res olve any w arranty i ssues. Should y our dealer re- quir e any additional assis tance they will cont ac t th e appropr iate pers on at Polari s. Thi s warr anty giv es you specifi c legal ri ghts, and you may also have other ri ghts whic h vary fr om state to state. If any of the abov e terms are [...]

179 INDEX AIR CLEANER 132 ........................ BA TTER Y INST A LLA TION 110 .............. BA TTER Y MAIN TENANCE 10 6 .............. BA TTER Y REMOV AL 10 9 ................... Brake A djustment 138 ....................... Brake F reeplay A djustment 140 ............... Brake L ever R7 ........................... BRAKE P ARKING 58 ...........[...]

180 INDEX Pre Opera tion Chec k R12 - R15 ................ PV T SYS TEM 62, 104 ...................... Rear Br ake R7 ............................ REAR SP RING ADJUSTME NT 131 ........... RIDER’S SECTION R1 ..................... RID ING 84-103 ........................... Ri ding Gear 72 - 73 ......................... RIDING ON SLIP PER Y SURF ACE[...]