Polaris Sportsman 9921483 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 2007 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 operation and care of your ne w A TV . Please review the information in this manual with any child who may opera[...]

4 We l c o m e Dear Childr en: Before you ride your new Pola ris A TV , there are some important things that you need to know . Y o ur parents and Polaris want you to enjoy riding your new A TV , and that's why yo u need to read and understand the in formation in your ow ner's manual. Ask your parents to explain any thing yo u don' t[...]

5 T able of Contents Safety . . . . . . . . . . . . . . . . . . . . . . 6 Y outh Section . . . . . . . . . . . . . . 17 Know Y our A TV . . . . . . . . . . . 18 Pre-Ride Check . . . . . . . . . . . 25 Riding Rules . . . . . . . . . . . . . 28 Adult Section . . . . . . . . . . . . . . . 33 Safety Decals . . . . . . . . . . . . 34 Driver W arnings . [...]

6 Safety Understand the W arnings Always follow the age guidelines for your A TV . Never allow a yo unger child to ride on o r drive the A TV . Make sure all operators have completed an approved A TV safety tra ining course such as the SVIA RiderCourse sm and understand all warnings and th e owner's manual before driving the A TV . Know Y our [...]

7 Safety Safety T ra ining A TV safety training is a to p priority for Pol aris. When you purchased your new A TV , your dealer instructed you on the authorized A TV RiderCour se sm available to you and your eligi- ble family members. This traini ng is included in the purchase price of your A TV . Polaris strongly encourages yo u and your ag e elig[...]

8 Safety The following signal words and symbo ls appear throughou t this manual an d on your v ehicle. Y our safety is involved when thes e words and symbols are used. Become familiar with their meanings before r eading the manual. The safety alert symbol , on your vehicle or in this manual, alerts you to the potential for injury . W ARNING The saf[...]

9 Safety WA R N I N G F ailure to follow the warnings in this manu al can result in severe injury or death. A Polaris A TV is not a toy and can be hazard ous to operate. T his vehicle handles differen tly than other vehicles such as motorcycles and cars. A co llision or rollover can oc cu r quickly , even during routine maneuvers like turning, o r [...]

10 Safety • Read this manual and all labels carefully . Follow all operating procedures. • Never operate an A TV without proper instruction. T ake a training cour se. Pur- chasers of a new Pola ris A TV and age eli- gible family members are entitled to take the A TV RiderCourse sm . Contact A TV Enrollment Express at (800) 887-2 887 or visit ww[...]

11 Safety • Never operate an A TV without wearing an approved helmet that fits properly . Always wear eye protectio n (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. • Never consume alcohol or drugs before or while operating this A TV . • Never operate at excessive speeds. Always travel at a speed whic[...]

12 Safety • Always follow proper procedures for turning as described in this manual. Prac- tice turning at low speeds before attempt- ing to turn at faster speeds. Do not turn at excessive speed. • Always have the A TV checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate the A TV on hills too steep f[...]

13 Safety • Always follow proper procedures for crossing the side of a hill as described in this manual. A void h ills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the A TV . Never attempt to turn the A TV around on any hill until you have mastered the turn- ing technique described in this manual on level g[...]

14 Safety • Always check for obstacles before oper- ating in a new area. Never attempt to operate over lar ge obstacles, such as rocks or fallen trees. Always follow proper procedu res when operati ng over obstacles as described in this manual. • A void operating the A TV through deep o r fast flowing water . If you cannot avoid water which exc[...]

15 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 vehicle, or make any other modifications to the vehicle for these purposes. Any modifications t[...]

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17 Y outh Section[...]

18 Know Y our A TV PA R E N T S : Polaris Y outh A T Vs are equipped 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 142. These units are not designed for adult use. Se rious da mage to the vehicle m[...]

19 Know Y our A TV Before you have an adult start the engine for you for the first time, let's l earn about the con- trols on your new A TV . 1. Engine S top Switch - When the engine is running, push this butt on 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 hor[...]

20 Know Y our A TV 4. Kick-S tart Lever - If your battery is too weak to start your A T V , 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 82. 5. Shift Lever - The shift lever is on the right side of you r A TV . Read about how [...]

21 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[...]

22 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[...]

23 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 off the engine. 10. T ether S trap and Switch - The tether strap must always be attached snugly to your right wrist and to your A TV every time you drive. If you fall of f your A TV , the tether st[...]

24 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 T V . 3. T urn th e key off.[...]

25 Pre-Ride Check W e're almost ready to have an adult start your A T V . 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 learn about these things now . n Make sure the throttle[...]

26 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 [...]

27 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[...]

28 Riding Rules Now you're ready to learn ab out riding your Po laris A TV . 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 pa y atten[...]

29 Riding Rules X Always wear the right kind of clothing an d safety gear when riding your A TV . Helmet: Y o ur 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[...]

30 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 T V is started. Make sure the area is safe all around 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[...]

31 Riding Rules X Never ride alone. An adul t should always be watching 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 coming to wards you. X D[...]

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

33 Adult Section[...]

34 Safety Decals W arning decals have been pl aced on the A TV for your protection. Read and follow th e instructions on each decal carefully . If any of th e decals shown in this manual differ from the decals on your A TV , always read and follow the instructions of the decals on the A TV . If any decal becomes illegible or comes off, co ntact you[...]

35 Safety Decals Operation W arning W ARNING Improper A TV use can resu lt in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gea r . Never use on public roads. Never carry passen gers. Never use with drugs or alcohol. NEVER operate: without proper trai ning or instruction; at speeds too fast for your skills or the co nditions[...]

36 Safety Decals Age W arning W ARNING • Kids under age 12 should NEVER operate this A TV . Kids under 12 have an increased chance of losing con- trol, which could result in severe inju ry or death. • Adult supervi sion is required. • Make sure operators follow Own er's Manual and labels. • Make sure operators wa tch the safety video o[...]

37 Safety Decals Outlaw 90 Tire Pressure W arning W ARNING IMPROPER TIRE PRESSURE OR OVERL OADING can cause loss of control, resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KP a ): FRONT 3 (20.7) REAR 3 (20.7) MAXIMUM WEIGHT CAP ACITY (Gross V ehicle W eight) INCLUDING MACHINE, DRIVER AND CARGO IS 453 LBS. (206 KG). +[...]

38 Safety Decals Sportsman 90 Tire Pressure W arning W ARNING IMPROPER TIRE PRESSURE OR OVERL OADING can cause loss of control resulting in SEVERE INJURY OR DEA TH. TIRE PRESSURE IN PSI (KP a): FRONT 3 (20.7) REAR 3 (20.7) MAXIMUM WEIGHT CAP ACITY (Gross V ehicle W eight) INCLUDING MACHINE, DRIVER AND CARGO IS 528 LBS. (240 KG). Reduce speed and al[...]

39 Safety Decals No P asseng er W arning W ARNING NEVER ride as a passenger . P assengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. + +[...]

40 Safety Decals Sportsman 90 Rack W arning W ARNING DO NOT TOW WI TH THIS VEHICLE. V ehicle damage or tipover may result causing severe injury or d eath. Maximum Rack Loads: F ron t 15 lbs. (6.8 kg) Rear 30 lbs. (1 3.6 kg) + +[...]

41 Safety Decals Clutch Cover Warning W ARNING NO STEP Moving parts haza rd under belt-clutch g uard. T o prevent 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 imbalan ce, and exces- sive engine RPM which can re[...]

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43 Driver W arnings Be sure to read all of th e following warnings about driving hazards and how to avoid them. These warnings are provid ed for your child's safety . Be sure to explain to your young driver that the following hazards MUST be avoided at all times.[...]

44 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating this A T V without proper instruction. WHA T CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the A T V properly in different situ ations and on diffe rent types of terra in. HOW TO AVOID THE HAZARD Beginning and inexperi enced oper ators[...]

45 Driver W arnings WA R N I N G POTENTIAL HAZARD F ailure to fo llow the age recomme ndations for this A TV . WHA T CAN HAPPEN Use by children of A T Vs t hat are not recommended for their ag e can lead to severe injury or death o f the child. Even though a child may be within the age group fo r which some A TVs are recommended, he or she may not [...]

46 Driver W arnings WA R N I N G POTENTIAL HAZARD Carrying a pa ssenger on this A TV . WHA T CAN HAPPEN Carrying a passenger g reatly reduces your ability to balance and control this A TV . Carrying a passenger could cause an a ccident, resulting in harm to you and/or your passenger . HOW TO AVOID THE HAZARD Never carry a passenger . The purp ose o[...]

47 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating this A TV on paved surfaces, inclu ding sidewalks, paths, parking lots an d driveways. WHA T CAN HAPPEN The A T V tires are desig ned for off-road use. Paved surfaces may seriously affect handling and control of the A TV , and may cause the vehicle to go out of co ntrol. HOW TO AVOID THE H[...]

48 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating this A TV on public streets, roads or highwa ys. WHA T CAN HAPPEN Y ou can collide w ith another vehi cle. HOW TO AVOID THE HAZARD Never operate this A T V on any paved or unpaved public street, road or highway . In many states it is illegal to operate A TVs on public streets, roads and hi[...]

49 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating this A TV wi thout wearing protective gear . WHA T CAN HAPPEN Operating without an approved helmet increases the risk of a severe head i njury or death in the event of an acci- dent. Operating witho ut eye protection and protective clothing can also result in injury . HOW TO AVOID THE HAZA[...]

50 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating this A T V after consuming alcohol or drugs. WHA T CAN HAPPEN Y our judgment could be seriously affected. Y ou may react more slowly . Y our balance and perception will be affected. Y ou cou ld have an acciden t. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while drivin[...]

51 Driver W arnings W ARNING POTENTIAL HAZARD Operating this A T V at excessive speeds. WHA T CAN HAPPEN Increases your chances of losi ng control of the A TV , which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed whi ch is proper for the terrain, visibil ity and operating condi tions; and your expe rience. WA R N I N G[...]

52 Driver W arnings WA R N I N G POTENTIAL HAZARD Attempting jumps and other stunts. WHA T CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps, or other stu nts. Avoid exhibition driving (don' t show off).[...]

53 Driver W arnings WA R N I N G POTENTIAL HAZARD Removing hands from handlebars or feet from footrests duri ng operation. WHA T CAN HAPPEN Removing even one hand or foot can make it harder to control the A TV or could cau se you to lose your balance and fall off th e A TV . If you remove a f oot from the footrest, your foot or leg may touch the re[...]

54 Driver W arnings WA R N I N G POTENTIAL HAZARD F ailure to use extra care when operating this A TV on unfamiliar terrain. WHA T CAN HAPPEN Y ou can come upon hidden rocks, bumps, or holes, without enough time to react. Th is could cause the A TV to overturn or go out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when ope rat[...]

55 Driver W arnings WA R N I N G POTENTIAL HAZARD F ailure to use extra caution when operating on exces- sively rough, slippery or loose terrain. WHA T CAN HAPPEN Operating on excessively ro ugh, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or ove rturn. HOW TO AVOID THE HAZARD Do not [...]

56 Driver W arnings W ARNING POTENTIAL HAZARD T urning improperl y . WHA T CAN HAPPEN Improper turns co uld cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures fo r turning as described in the owner's ma nual. Practice turning at slow speeds before attempting to turn at faster spee[...]

57 Driver W arnings WA R N I N G POTENTIAL HAZARD Climbing hills improperly . WHA T CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures fo r climbing hills as described in the Owner's Manual be ginning on page 98. Always check the terrain carefull y before you start[...]

58 Driver W arnings WA R N I N G POTENTIAL HAZARD Going down a hill imp roperly . WHA T CAN HAPPEN Driving downhill improperly c oul d cause loss of control or A TV overturn. HOW TO AVOID THE HAZARD Always follow proper procedures fo r going down hills as described in the Owner's Manual. See pag e 104. NOTE: A special technique is requi red wh[...]

59 Driver W arnings WA R N I N G POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHA T CAN HAPPEN Improperly crossing or turning as hills cou ld cause loss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the A T V around on any hill until you've mastered the turn ing technique (on level ground) as described i[...]

60 Driver W arnings WA R N I N G POTENTIAL HAZARD Stalling, rolli ng backwards or impr operly dismo unting while climb- ing a hill. WHA T CAN HAPPEN: The A TV could overturn and cause injury . HOW TO AVOID THE HAZARD: Maintain steady speed when climbing a hill. If you lose all forward speed : Keep your weight uphill. Apply the front brakes graduall[...]

61 Driver W arnings W ARNING POTENTIAL HAZARD Skidding or sliding. WHA T CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedl y , the A TV could overturn. HOW TO AVOID THE HAZARD On slippery surfa ces such as ice , travel sl owly and use extra caution to reduce the chance of skidding or sliding out of c[...]

62 Driver W arnings W ARNING POTENTIAL HAZARD Riding on frozen lakes and rivers. WHA T CAN HAPPEN Severe injury or death can result if the A TV and/or the operator br eak through the ice. HOW TO AVOID THE HAZARD Never ride your A TV on a frozen body of water . WA R N I N G POTENTIAL HAZARD Operating this A TV with improp er tires, or with improper [...]

63 Driver W arnings WA R N I N G POTENTIAL HAZARD Operating the A T V through deep or fast-flowing water . WHA T CAN HAPPEN Tires may float, causing loss of traction and loss of control, which coul d lead to an accident or over- turn. HOW TO AVOID THE HAZARD Avoid operating the A T V through deep or fast-flowing water . If it's unavoidable to [...]

64 Driver W arnings W ARNING POTENTIAL HAZARD Overloading the A TV . WHA T CAN HAPPEN Overloading the A TV could cause changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this AT V . If equipped with racks, cargo shou ld be prop- erly distributed and securely attached. WA R N I N G[...]

65 Driver W arnings W ARNING Safe operation of this rider - active vehicle requires good j udgement and physical ski lls. P ersons with cogni tive or physical disa bilities who operate th is vehicle have an increased risk of overturns and l oss of control which could result in severe injury or death. Do not allow disabled perso ns to operate this v[...]

66 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[...]

67 F eatu res and Con trols Main K e y 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 engine is not running. WA R N I N G Leaving the keys in the ignition can lead to una uthorized use of the vehicle resul ting in serious injury or death[...]

68 F e atures and Controls Engine Stop 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 . NOTE: Both the main switch and th e engine stop switch shut off al l electrical power to the[...]

69 F eatu res and Con trols Horn Button Use the horn for emer gencies and to let others know you’re near . Engine Start 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 w[...]

70 F e atures and Controls Throttle Controls WA R N I N G Operating an A TV with sticking or im pro perly operating throttle con trols could cause a n accident and lead to severe injury or death. Never start or operate an A TV with a sticking or imprope rly operating throttle. Always contact your dealer for service if throttle p roblems arise. F ai[...]

71 F eatu res 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 s[...]

72 F e atures and Controls Shift 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 mov- ing. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you ex perience any [...]

73 F eatu res and Con trols CA UTION Do not attemp t to shif t the transmission while the vehi cle is moving or damag e to the transmission could result. Always shift when the vehicle is statio nary and the engine is at idle. Always place the transmissio n in gear wi th the park i ng brake applied and turn the vehicl e off when- ever the vehicle is[...]

74 F e atures and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The ri ght lever controls the front brakes. WA R N I N G Applying only one brake cou ld cause loss of co ntrol and result in serious injury or death. Always apply both brakes at the same tim[...]

75 F eatu res and Con trols Brakes Pa r ki n g B r a k e 1. Squeeze the left brake leve r . 2. Push the parking brake lock down to lock the brake lever in place. 3. T o release the parking brake lock, squeeze and release the brake lever . The parking brake will release automatically . WA R N I N G Operating the A T V while the parki ng brake is eng[...]

76 F e atures and Controls Brakes Pa r ki n g B r a k e 1. Always shift the transmission to neutral an d lock the parking brake before starting the engine. 2. After the eng ine has w armed enou gh fo r operation, shift to the desired gear . 3. Release the parking brake an d gently apply the throttle. 4. Always lock the parking brake whenev er the v[...]

77 F eatu res and Con trols Lights Indicator Li ghts Indicator lights on the A TV let you know when yo ur A TV is in neutral or reve rse. WA R N I N G P olaris Y outh A TVs are not eq uipped w ith lights th at are designed for drivi ng in the dark. Do not operate this A TV after dark. Use caution and drive at reduced speeds in conditions of reduced[...]

78 F e atures and Controls F uel System WA R N I N G Gasoline is highly flammable and explosive under certain con ditions. • Always exercise extreme cautio n whenever hand ling gasoline. • Always refuel with the engine stopped, and ou tdoors or in a well ventilated area . • Do not smoke or allow open flames or sparks in or near the area where[...]

79 F eatu res and Con trols F uel System WA R N I N G The engine exhaust from this product contains chem icals known to cause cancer , birth defects or other reproductive harm. Operate this ve hicle only outdoo rs or in well-ventilated areas.[...]

80 F e atures and Controls F uel 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 178 for fu el tank capacity . Gas Cap[...]

81 F eatu res and Con trols F uel V alve The fuel valve is located on the left side of the A TV . It has three settings. OFF : For vehicle storage a nd when transp orting. ON: F or normal operation. RES: F or reserve supply if main supply is exhausted. NOTE: The reserve setting all ows operation for approximately 7-10 miles (11-16 km). Always refil[...]

82 F e atures and Controls Kick-Start 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 T V . [...]

83 Break-in P eriod The break-in period for your new Polaris 4-cycl e A TV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasolin e. No single action on your part is as important as following the pro cedures for a proper break-in. Careful treatment of a new engine will result in more ef ficie[...]

84 Break-in P eriod 1. Fill the fuel tank with gasoline. See page 78. 2. Check the oi l level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 125. 3. Drive slowly at first. Select an open area t hat allows room to familiarize yourself wi th vehicle operation and handling. 4. V ary throttle positions. Do no[...]

85 Pre-Ride Inspection WA R N I N G If a proper inspection is not done before ea ch us e, severe injury or dea th could result. Always inspect the A TV be fore each use to ensu re it's in proper ope rating condition. Pre-Ride Checklist Item Remarks P age Brake system / lever travel Ensure proper oper ation 145, 149 F r ont suspen sion Inspect,[...]

86 Pre-Ride Inspection Pre-Ride Checklist Item Remarks P age Tires Check cond ition and pres sure 159 Wheels / fasteners Inspect, en sure fa stener tightness; check that axle nuts are secu red by cot- ter pins 161, 162 F uel and oil Check and fill as needed 78, 80 Throttle Check for proper operation 25, 70, 71 Engine stop switch Check for proper fu[...]

87 Pre-Ride Inspection Pre-Ride Checklist Item Remarks P age Air filter , pre-filter In spect, clean or replace 156 Drive chain Check condition and slack; refer t o drive chain adju stment 153 F rame nuts, bolts, fasteners In spect, ensure tightness -- Loose or damag ed components Visually inspect for any da maged com- ponents or loose fastene rs -[...]

88 Starting the Engine WA R N I N G Engine exhaust contains poisonous carbo n monoxide and can cause loss of consciousness result- ing in severe injury or de ath. Never run an engine in an enclosed area. CA UTION Operating the A TV immediately after starting could cause engine d amage. Allow the engine to warm up for several minutes before operatin[...]

89 Starting the Engine 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 and attach the tether strap to the A TV and to your right wrist. NOTE: The choke is fully on when th e lever is pushed completely to the left. Th e choke is off when the lever is pushed completely to the right.[...]

90 Starting the Engine 8. Squeeze the rear brake lever and press the starter button. NOTE: The rear brake lever must be eng aged or the engin e won't start. 9. Activate the starter for a ma ximum of five s econds, releasing the button when the engine starts. If it doesn't start, release the starter , wait five seconds, then activate for a[...]

91 Stopping the Engine 1. Release the throttle completely and brake to a complete stop. 2. Shift the transmission to neutral. 3. S top the engine. NOTE: There are three ways to stop the engin e. • T urn the key off . • Push the engine stop switch down. • Pull the tether strap off the A TV . NOTE: T o avoid draining the battery , always turn t[...]

92 Driving Safely 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. [...]

93 Driving Safely 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[...]

94 Driving Safely 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 . [...]

95 Driving Safely 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, lea[...]

96 Driving Safely Driving on Slippery Surfaces WA R N I N G F ailure to exercise care when opera ting on slippery su rfaces can result in loss of tire traction and cause loss of control, acciden t, and serious injury or dea th. Never apply the brakes during a skid. Do not operate on excessi vely slippery surfaces. Always reduce speed and use add it[...]

97 Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as we t trails or loose gravel, or d uring freezing weather , follow these precautions : 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a ski[...]

98 Driving Safely Driving Uphill WA R N I N G Braking and handling are greatly affe cted when oper ating in hilly terrain. Improper proce dure could cause loss of control or overturn and result in seri ous injury or death. Avoid climbing steep hills (15 ° ma ximu m). Use extreme caution when operatin g on hills, and follow proper ope rating pro ce[...]

99 Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void steep hills (15 ° maximum). 3. Keep both feet on the footrests . 4. T ransfer your weigh t forward. 5. Proc eed at a steady rate of sp eed and throttle opening. 6. Remain alert and b e prepared t o take emergen cy actio[...]

100 Driving Safely Driving Across Hillsides WA R N I N G Improperly crossing hills or turning on hills can resu lt in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.[...]

101 Driving Safely Driving Across Hillsides Sidehilling can be a dangerous type of driving an d should be avoided if at all possible. If you do enter into a situation where sidehillin g is necessary , follo w these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keep- ing your feet on the footrests[...]

102 Driving Safely T urning Around on a Hill If the vehicle stalls while climbi ng a hill, never back it down th e hill! One maneuver that can be used when it's necessary to turn around while clim bing a hill is the K-turn: 1. S top and lock the parking brake while maintaining b ody weight uphill. 2. Shift the transmission to neutral. 3. Shut [...]

103 Driving Safely T urning Around on a Hill 5. S taying uphill of the A TV , turn the handle- bars full left. 6. While holding the brak e, release the park- ing brake lock and slow ly release the brake, allowing the A TV to roll around to your right until it's pointing across the hill or slightly downward. 7. Lock the parking brak e and remou[...]

104 Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. T ransfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the front and rear brakes at the same time, and very slightly , to aid in slowing. W ARNING Excessive speed can cause loss of control and lead to serious in[...]

105 Driving Safely P arking on a Hill or Incline A void parking on a hi ll or incline i f pos- sible. If it's unavoidable, follow these precautions: 1. T urn the en gine off. 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.[...]

106 Driving Safely Driving Through W a ter Y our A TV can safely op erate through sh allow water . The recommended maximum depth for your A TV is below the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths before driving through water . 2. If crossing a stream, choose a crossing where both bank[...]

107 Driving Safely Driving Through W a ter A void operating your A TV through deep or fast flo wing water . If the A TV is operated in deeper wate r than reco mmended, it's critical to have it servic ed as outli ned in the mainte- nance chart begin ning on page 1 14. The followin g areas need special attention: engine oil, gearcase oil, front [...]

108 Driving Safely Driving Over Obstacles Be alert! Look ahead an d learn to read th e ter- rain you're traveling on . Be constantly alert for hazards such as logs, rocks and low hang- ing branches. W ARNING Severe injury or death ca n result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visi ble. T[...]

109 Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly . 2. Apply the b rakes light ly for stopping. 3. A void turning at sharp angles. 4. Always avoid ba cking downhi ll. 5. Never open the throttle suddenly while backing. 6. Always look left, right and be hind the A TV before back ing. WA R N I N G [...]

110 Driving Safely 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. • Place 1/3 of the car go weight on the front rack and 2/3 on th e rear rack. Carrying load s on only one rack increases the chanc[...]

111 Driving Safely Hauling Cargo • Never exceed the weight capacities for the ve hicle. Capacities are listed in t he specifica- tions section begin ning on page 1 78. • Secure all cargo before driving. Loose car go ma y move or shift, which could cause loss of control or a tipover . Use suitable tie-downs or rope to secure the cargo. Do not al[...]

112 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 requirements (40 CFR 205) and local noise level require- ments. Operation on Public Lands in the U.S.A . Y our Polaris vehicle has a spark arrestor that was tested and [...]

113 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 P[...]

114 Maintenance P eriodic 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[...]

115 Maintena nce P eriodic 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 . NOTE: Service and adjustmen ts are critic al. If you're not familiar with safe servi ce and adjustment procedures,[...]

116 Maintenance P eriodic Maintenance Chart Maintenance Chart Ke y X Perform these operations more often under se vere use, such as in dir ty or wet co ndi- tions, to purg e water or dirt contamination fro m grease fittings and other critical components. E Emission-related service (Failure to conduct this maintenance will not void t he emis- sions [...]

117 Maintena nce P eriodic Maintenance Chart Item Main tenance Interv al (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. 85 X F ront suspension -- Daily -- X Rear suspension -- Daily -- Tires -- Dai ly --[...]

118 Maintenance P eriodic 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 Main tenance Interv al (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) Drive chain -- Daily -- Inspect daily; adjust [...]

119 Maintena nce P eriodic Maintenance Chart Item Main tenance Interv al (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) Battery 20 Monthly 200 (320) Check terminals; clean; test 166 X Engine oil change 30 6 M 300 (480) Drain and change the oil 126 X T ransmission oil 40 12 M 400 (640) Drain and change the oil 130 X Oil pre-filt[...]

120 Maintenance P eriodic 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 Main tenance Interv al (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) E Carburetor air intake ducts/flange 50 6 M 50[...]

121 Maintena nce P eriodic Maintenance Chart Item Main tenance Interv al (whichever comes first) Remarks See Pag e Hours Calendar Miles (Km) X Wiring 100 1 2 M 1000 (1600) Inspect for wear , r outing, security; apply dielectric grease to connec- tors subjected to water , mud, etc. -- Q Clutches (drive and driven) 100 1 2 M 1000 (1 600) Inspect; cle[...]

122 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 124. Gearca se (T ransmission ) Oil Level Premium AGL Synthetic Gearcase Lub e See page 130. Drive Chain P olaris Chain L ube or SAE 80/90 See page 153[...]

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

124 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 1 14. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 18 2 for the part numb ers of Polaris pro ducts. Under These Opera tin[...]

125 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. NOTE: A rising oil level betw een checks in coo[...]

126 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. CA UTION Hot oil can cause ser ious burns to skin. Do not allow hot oil to come into contact with skin.[...]

127 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 sealing washer on the plug. NOTE: The sealing surfaces on [...]

128 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. NOTE: See the spe cifications section beginning on page 17 8 for cap acities. 12. Reinstall the dipstick. 13. S tart the engine. All ow it to idle for on[...]

129 Maintena nce F uel 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 1 14. Do not attempt to clean the fuel filter .[...]

130 Maintenance T r ansmission 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 1 14. Polaris recommends the use of[...]

131 Maintena nce T r ansmission 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 bot[...]

132 Maintenance Spark Plugs Refer to the specifications section beginning on page 1 78 for spark pl ug and gap specifica- tions. Spark plug condition is indicativ e of engine operat ion. The spark plug firing end condition should be read after the engine has been warmed up an d the vehicle has been drive n at higher speeds. Immediately check the sp[...]

133 Maintena nce Spark 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. NOTE: The tip should not be white. A white insulato r ti p indicates overheating, caused by use [...]

134 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 it's impossible to take your A TV to a dealer before starting it, follow the steps outlined below . 1. Move the A TV to dry land or at t he ve ry least, to water below the footre[...]

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

136 Maintenance Constant V ariable T ransmission (CVT) System WA R N I N G F ailure to comply with the instru ctions in this warning can result in severe injury or death. Do not modify any compo nent of th e CVT system. Doin g so may reduce its str ength so that a failu re may occur at a high speed. The CVT system has been precision balanced. Any m[...]

137 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[...]

138 Maintenance Spark 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 1 14. WA R N I N G F ailure to heed these warnings could result in serious injury or de ath. Do not perform service on the s park arrestor while the system is hot. Allow componen[...]

139 Maintena nce Spark 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 arre[...]

140 Maintenance Carburetor IMPOR T ANT : Y our Polaris A TV is calibrated at the factory for optimal performance at alti- tudes ranging from zero to 6,000 feet (18 00 m) and temperatures of +4 0 degrees F . (4 degrees C.) or high er . Above 6000 feet (180 0 m) the engine air/fuel mixture becomes ov erly rich and the engine loses approximately 3% of[...]

141 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[...]

142 Maintenance Speed 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 late r , even at the consumer's r equest, r emove [...]

143 Maintena nce Speed 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[...]

144 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[...]

145 Maintena nce Brake F reeplay 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 1 14. If the freeplay 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[...]

146 Maintenance Brake F reeplay 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 n[...]

147 Maintena nce Brake F reeplay 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[...]

148 Maintenance Brake F reeplay 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 bra[...]

149 Maintena nce Brake Lever T r avel Check brake lever travel at the intervals re commended in the Period ic Maintenance Chart beginning on pa ge 1 14. When freep lay specifications can n o 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 [...]

150 Maintenanc e To e A l i g n m e n t Use the fo llowing proc edure to check the toe ali gnment of the vehicl e. The reco mmended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. 1. Set the handlebars in a straight-ahead po sition. NOTE: The steering frog can be used as an indi cator of whether the handl ebars are strai ght. The frog sho[...]

151 Maintena nce T oe Alignment 3. T ie an elas tic string around the stands, making sure the string just to uches the side surface of the rear tires on each side of the vehicle and goes around th e stands in front of the vehicle. 4. Measure the distance fro m the string to the rim at the front and rear of the front rim. Rear mea- surement shou ld [...]

152 Maintenance Steering Inspection Check the steering a ssembly pe riodically 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 Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spr[...]

153 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 Maintena nce Chart beg inning on p age 1 14. Lubricate more often under severe use, such as in dirty or wet conditions. See page 182 for the part numbers of Polaris products[...]

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

155 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 adjuster cloc kwise to 1/4"-1/2" (6-12 mm) deflection. 4. T ighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). 5. T ighten the four rear housing mount bolts to 4 3 ft. lbs. (60 Nm). C[...]

156 Maintenance Air Filter 1. Remove the seat. See page 21. 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 [...]

157 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. CA UTION Never operate the A TV with the filt er element removed. Dirt wil l ent er the engi ne causing rapid wear and severe damage to the engine.[...]

158 Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Remove the pod to access the handlebar b olts. Loosen the four bolts. 2. Adjust the handlebar to th e desired height. Be sure the handlebars do not hit the gas tank or any other part of the vehicle when tu rned fully to the left or right. 3. Lightly ti ghte[...]

159 Maintena nce Tires WA R N I N G Operating your A TV with worn ti res, improperly inflated tires, non-stand ard tires or impro perly installed tires will affect vehicle handli ng and could cause an accident resulting in seriou s injury or death. Maintain proper tire pressure as describ ed on the decal on your A T V and in the owner's manua [...]

160 Maintenance Tire T r ead Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. S top the engine and lock the parking b rake. 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/[...]

161 Maintena nce Wheel Installation 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 b[...]

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

163 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 L amp[...]

164 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[...]

165 Maintena nce Daytime Running Lights L amp 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[...]

166 Maintenance Battery The battery in your Polaris A TV is a sealed ba ttery . The sealing strip cannot be removed. Never add water to this type of battery . Keep the battery terminals and connections free of corrosion. If c leaning is necessary , remove the corrosion with a stif f wire brush. W ash with a solution of one tablespo on baking soda a[...]

167 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 .[...]

168 Maintenance Battery Battery Installat ion and Connections 1. Set the battery in its holder . 2. Connect and tighten the red (positive) cable first . 3. Connect and tighten the bl ack (negative) cable last. 4. Attach the hold-down strap. 5. V erify that cables are properly routed. NOTE: When install ing a new battery , make sure it's fully [...]

169 Maintena nce Cleaning Keeping your A TV clean will not only improve its appearance but it can also extend the life of various compon ents. CA UTION High water pressure may damage componen ts. P olaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, includin g insect repellents and chemicals, will[...]

170 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[...]

171 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 seals •B r a k e s • Cab [...]

172 Maintenance Po li s h i ng 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 pad[...]

173 Maintena nce Storage Exterior Make necessary repairs and c lean the vehicle as recommended. See page 169. 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 charg[...]

174 Maintenance Storage Stabilize the F uel 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 reatm ent or Polar[...]

175 Maintena nce Storage Engine Oil Change the oil. See page 126. 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 1 1 4. • T ransmission Oil •E[...]

176 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recomme nded in the Periodic Main- tenance Chart beginning o n page 1 14. 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 the [...]

177 Maintena nce T r ansporting 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 sporting unit securely w ith suitable straps or rop[...]

178 Specifications Outlaw 90 Rider Capacity/M aximum Weight 1 Rider/1 70 lbs. (7 7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication We t Sump Oil Capacity 30 oz. (900 ml) F ue l Capacity 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 Automati[...]

179 Specifications Outlaw 90 F ront/Rear Brakes Drum P arking Brake Mechanic al Lock F r ont Tir es 19 x 7 - 8 (3 p si) Rear Tires 18 x 9.5 - 8 (3 psi) 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 cm) at swing arm, 7[...]

180 Specifications Sportsman 90 Rider Capacity/M aximum Weight 1 Rider/1 70 lbs. (7 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 Automatic [...]

181 Specifications Sportsman 90 F r ont Rack Capac ity 15 lbs. (6.8 kg) Rear Rack Capacity 30 lbs. (13.6 kg) F ront/Rear Brakes Drum P arking Brake Mechanic al Lock F r ont Tir es 19 x 7 - 8 (3 p si) Rear Tires 18 x 9.5 - 8 (3 psi) Dry W eight 289 lbs. (131 kg) Length/Width/Height 61.75" (1 57 cm) / 36.75" (93 cm) / 38.5 " (98 cm) Wh[...]

182 P olaris Products 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 -4 0 Oil (qt/.95 l) 2872176 Semi-Synthetic 20W -4 0 Oil (gal/3.8 l) 2870791 Fogging Oil, Aerosol Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic G earcase Lubr[...]

183 P olaris Products 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[...]

184 T roubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine T urns Over , F ails to Start 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 the fuel system and refuel [...]

185 T roubleshoot ing Engine Doesn’t T urn Over Engine Pings or Knocks Possible Caus e Solution Low battery voltage Rechar ge ba ttery with .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 w[...]

186 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 [...]

187 T roubleshoot ing Engine Runs Irregularl y , Stalls 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 connections[...]

188 T roubleshooting Engine Runs Irregularl y , Stalls 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 Ov[...]

189 T roubleshoot ing Engine Stops or Loses P ower 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 replac[...]

190 W arranty 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 nty cov[...]

191 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[...]

192 W arranty W ARRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION T O THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES N[...]

193 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). [...]

194 W arranty EXPORTED VEHICLES EXCEP T WHERE SPECIFICAL L Y REQUIRED 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. Deal[...]

195 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 e hicles importation rules vary c onsiderably from co untry to country . Y ou may be required to present do cumentat ion of your m[...]

196 W arranty U.S.A . EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Uti lity V ehicle (ORUV) emissions limited warranty is in additi on 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 with[...]

197 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 ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF[...]

198 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[...]

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

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

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

202 Index A Accessories . . . . . . . . . . . . . . . . . . 177 Age Warning . . . . . . . . . . . . . . . . . 36 Air Filter . . . . . . . . . . . . . . . . 156-157 Axle and Whe el Nuts . . . . . . . . . . 162 B Battery Installation/Connections . . . 168 Removal . . . . . . . . . . . . . . . 167 Storage . . . . . . . . . . . . . 168, 173 Boots . . .[...]

203 Index I-J Indicator Light . . . . . . . . . . . . . . 164 Indicator Lights . . . . . . . . . . . . . . . 77 K Key Switch . . . . . . . . . . . . . . . . . . 67 Kick-Start Lev er . . . . . . . . . . . 20, 82 K-Turn . . . . . . . . . . . . . . . . . . . . 102 L Lamp Replacement Daytime Running Lights . . 165 Indicator Light . . . . . . . . . . 16[...]

204 Index S Switches Engine Start Button . . . . . . . . 69 Engine Stop Switch . . . . . 19, 68 Horn Button . . . . . . . . . . . . . . 19 Ignition Swi tch . . . . . . . . . . . 23 Main Key Switch . . . . . . . . . . 67 Tether Switch . . . . . . . . . . . . 23 T Tail Light . . . . . . . . . . . . . . . . . . . 163 Tether Strap . . . . . . . . . . .[...]