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Polaris Sportsman 90 Motorcycle User Manual

1. 2001 SCRAMBLER 50 MAIN SWITCH nm FT HANI int APRES f swiTCH OLL LIGHT pa SAFETY EET AND o SWITCH Lai eek EE ES SIMPLIFY TRACING IN DIAGRAM 95 or ee ICLOSE PUSH Cn I qu OPEN WHEN TO RUN NI LM THROTTLE LEVER RELEASED ch i d ch E 28 i N fu START MOTOR 1 L 535 PE REGULATOR b 7 RECTIFIER p Se B Hh 23 smia ss ur Hr mi E OE x euer snow BLACI 4 ur Pc LOCATED ABOVE RIGHT LACK SIDE OF ENGINE e Eb seuice sprice Spice serice TY Ad RESTSTOR 14 17 oeg L zi N E H is 16 JE 35 TL 3 6 8 FONT Site 85 18 rn S2 Sassen 8 22 28 SIGE CARBURETOR SPARK PLUG Lo IGNITION a m E COIL e 12 BLK peso TT BOK LOCATED AT FRONT OF EN
2. 145 DAILY PRE RIDE INSPECTION 20 21 81 83 Drive Chain Adjustment 153 154 ENGINE ELECTRICAL SWITCHES 49 Engine Start 51 Engine Stop R4 50 Front Brake er sage ge trance ies R7 Fuel Safety Roe alee aud RE 65 FUEL SYSTEM 63 obere RT HER ARE R6 GENERAL SAFETY AND DESCRIPTION OFLABELS 5 18 HANDLEBAR ADJUSTMENT 128 Ignition Switch R8 INDICATOR LIGHTS 56 Kick Starfet i cached cesa ede eee de R5 69 KNOW YOUR MACHINE R2 R11 Load Capacity e edited order trees 71 80 LUBRICANT 2 Cycle 67 LUBRICATION RECOMMENDATIONS 122 123 Main cece eee ee eee 49 Battery ue eds iere m n Sue no et Re 106 111 Maintenance 115 161 MAINTENANCE RECORD 126 MAINTENANCE SCHEDULE 115 118 MAKING TURNS 86 NOISE CONTROL SYSTEM 112 114 OIL SYSTEM 63 Oil System ilm eSI URS E ES PESO 66 OPERATION WARNINGS 19 46 PARKING ON AN INCLINE 102 INDEX Pre Operation R12 R15 PVT SYSTEM csomo oenina i gee ad Geen 62 104 Rear 03 sit p ice or Ne toes ane eas R7 REAR SPRING ADJUSTMENT 131 RIDER S SECTION R1 RIDING
3. eoe 84 103 Riding Gear 72 73 RIDING ON SLIPPERY SURFACES 88 SAFETY WARNING AND OPERATION DECALS 10 SIDEHILLING 92 SPARK PLUGS 142 SPECIFICATIONS 162 168 STARTING COLD ENGINE 70 Starting the Engine 70 71 STEERING INSPECTION 134 TetherStrap rtt Rt RI ht R9 EHEGUTS Lea eter aba ede Cle tte x 53 Throttle Cable Adjustment 135 141 THROTTLE LEVER 54 TIRE INSPECTION 152 180 Toe Alignment 136 137 ree mer RE RH INS 115 TORQUE SPECIFICATIONS 130 TRAIL OBSTACLES 100 TRANSMISSION LUBRICATION 146 TRANSMISSION OIL CHANGING PROCEDURE 147 TRANSPORTING 160 TRAVELING DOWNHILL 94 TRAVELING 90 TROUBLESHOOTING 171 172 TURNING AROUND 96 UNDERSTANDING WARNINGS 1 4 Understanding Warnings R16 R20 VEHICLE IDENTIFICATION NUMBERS 47 48 WARRANTY 173 178 WHEEL INSTALLATION 149 151 Wheel Nut Torque 150 WHEEL REMOVAL 149 WIRING DIAGRAM 169 170
4. Internal Drink large quantities of water or milk Follow with milk of mag nesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 107 BATTERY Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level Maintain marks between To refill use only distilled water Tap water contains lower level minerals which are harmful to a battery marks 108 Battery Removal 1 Disconnect hold down straps holding the electrical box and battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Lift the battery out of the ATV being careful not to tip it sideways and spill electro lyte ACAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV Indicates a potential hazard which could AWAR N G result in severe injury or death 109 BATTERY Battery Installation and Connections A WARNI
5. Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening Drive slowly practice maneuvering and using the throttle and brakes on level sur faces 85 RIDING Making Turns 86 RIDING Practice making turns at slow speeds Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer foot rest This technique alters the balance of traction between the rear wheels allow ing the turn to be made smoothly A WARNING Avoid turning at sharp angles Tipover and severe injury may result 87 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or dur ing cold freezing weather special attention must be paid to prevent vehicle turnover Always 88 _ RIDING Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a sk
6. 55 CONTROL AND PARTS FUNCTIONS Switches Each Polaris ATV has a main switch It is located on the right hand side of the machine or headlight pod and operated with a key Indicator Lights Each Polaris ATV has indicator lights This model has a low oil warning light When this red dot is lit it is indicating a low oil level 56 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes To activate the rear brake A squeeze the left hand lever to ward the handlebar The front brakes B are activated by squeezing the lever on the RH handlebar A WARNING Always apply both brakes at the same time or loss of vehicle con trol can occur resulting in seri ous injury or death 57 CONTROL AND PARTS FUNCTIONS Parking Brake A WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the park ing brake is left on while the ATV is operated Setting the Parking Brake 1 Squeeze the left hand brake lever A 2 Pushthe park brake lock B down This will pre vent the lever from returning to the released position 58 CONTROL AND PARTS FUNCTIONS 3 Torelease the parking brake lock squeeze the brake lever The parking brake will release automatically Important Safeguards NOTE This vehicle has a PVT system which is always in forward Always lock the park brake before starting the engine Always lock the
7. All brakes check operation adjustment Throttle check for free operation and closing a A O N Brakelight check for proper operation DAILY PRE RIDE INSPECTION 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Operators helmet goggles and clothing Indicates a potential hazard which could AWAR N result in severe injury or death 21 OPERATION WARNINGS 22 4 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD Follow the age guidelines printed on your machine OPERATION WARNINGS A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Greatly redu
8. them toward the handlebar and then letting it go They should come right back to where they were before you squeezed Ifthey go back slowly or stay on your brakes are sticking If you have sticky brakes do not start the engine You could get hurt if you ride when you have sticky brakes Have an adult or your Polaris Dealer fix the sticky brakes X If you have used the storage area under the seat make sure the seat is locked and in place PRE RIDE CHECK 4X Have an adult check the gas level to see if your ATV needs more Children should never add their own gasoline This should always be done by an adult Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owner s Manual Always have adult put gas in your machine Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running It could burn you Children should never check the oil on their own An adult should be in charge of keeping the gas and oil levels to the full marks PRE RIDE CHECK Y This last check is done with the engine running You must check to make certain that ALL THREE WAYS TO STOP your ATV 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 RIDING RULES Now you are ready to learn about riding a ATV You will learn what you can do and what you cannot do The adult
9. 10 mm 20 mm Scrambler 50 1 39 15 30 2 5 9 9 mm 3 8mm 7 6mm 140 MAINTENANCE Throttle Cable Adjustment Always check the throttle for smooth operation before riding Periodically check the throttle DM freeplay It should be kept bet ween 1 16 and 1 8 1 5mm XC 3 2mm C If adjustment is re quired turn the adjustment nut D until the freeplay falls in to the ac D ceptable limit Indicates a potential hazard which could AWAR N G result in Vore injury or death 141 MAINTENANCE Spark Plugs The spark plug required for this machine is NGK BP7HS or NGK BPR7HS Incor rect spark plug gap can cause the spark plugs to foul The spark plug gap should be between 0 6 0 7 mm The spark plug and its condition is indicative of engine operation The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color 1 Normal The 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 insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 142 MAINTENANCE 2 Wet Fouled The insulator
10. Electronic models is in Throttle Control ugg Malfunction Water in Fuel Contact Your Dealer Clean Engine Exterior Contact Your Dealer 172 WARRANTY LIMITED WARRANTY Polaris Industries Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited war ranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transfer rable to another consumer during the warranty period through a Polaris dealer There is a charge of 35 00 payable to Polaris Industries Inc 173 WARRANTY REGISTRATION Atthe time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dea
11. Front Suspension Rear Suspension 164 Specifications Scrambler 90 A arm with 2 5 cm of travel Spring over shock with 2 5 cm of travel SPECIFICATIONS Specifications Scrambler 90 Front and Rear Tires PSI Dry Weight 233 7 Ibs 106 kgs Length 56 1 142 4 cm 34 86 3 cm Height 36 1 91 8 cm Brake Ligh Cow Oi Ligh 165 SPECIFICATIONS Specifications Sportsman 90 Displacement Engine Oi Capaciy Rider Capacity 1 Starting Electric with kick start backup Transmission Automatic CVT Front Suspension A arm with 2 in 5 cm of travel Rear Suspension Spring over shock with 2 in 5 cm of travel Fuel Capacity 1 3 ga 5 Itr 166 SPECIFICATIONS Specifications Sportsman 90 Rear Tres PSI 37 Turning Radius 98 4 250 cm Dry Weight 238 1 16 108 kgs Length 57 6 146 3 cm 34 4 87 4 cm Height 36 6 93 cm Brake Light 167 SPECIFICATIONS Specifications Sportsman 90 ETT Front Rack Capacity 10 Ib 4 5 kgs Rear Rack Capacity 20 Ib 9 kgs Accessories There are a wide range of Polaris Accessories available for ATVs Contact your Polaris dealer to find out about the accessories available for your machine 168 WIRING DIAGRAM
12. KNOW YOUR MACHINE 3 Kick Starter B If your battery is too weak to start your machine you can push on this with 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 KNOW YOUR MACHINE 4 Gas Cap This is where the gas goes that will run your ATV Your ATV will not run without gas Only adults should fill the gas tank KNOW YOUR MACHINE 5 Brake Lever C Squeeze this towards the handle bar to make your ATV slow down or stop The right hand lever C 1 controls the front brake The left hand lever C 2 controls the rear brake To slow down or stop squeeze both brake handles at the same time Always apply both brakes at the same time or loss of vehicle con trol can occur resulting in serious injury or death Always take your thumb off the throttle control when you pull the brake lever KNOW YOUR MACHINE 6 Ignition Switch This key must be turned on before pushing the starter button You can also use this key to turn off the engine You can find it on the Right hand side of the Scramblers D and on the pod of the Sportsman E KNOW YOUR MACHINE 7 Tether Strap Switch This must always be attached snugly to your right wrist and your machine when you are riding If you fall off your ATV the tether will pull off the switch and the engine will stop Put one end of the tether strap around
13. MOTOR i EE REGULATOR MM RECTIFIER 23 p I iE 23 E uH amp s 33 HM Ex po we x mS 15 1 1 YR 1 BROWN Light stue Ut LOCATED ABOVE RIGHT 2 BLK eel SIDE OF ENGINE xS SPLICE a 585 17 RESISTOR 1 iu pis WR We 10 BLACK rae as quu i 5 SPLICE CARBURETOR Plus im IGNITION su ee COIL eo atx pec TOT BOY LOCATED FRONT 13 BLK h OF ENGINE 1 44 WBLU BRAKE x imd SWITCH EET e a S417 m 31 GRY Cos one E EE o gt 288 LOCATED LEFT TAIL LAMP 27 BRATE LEVER BATTERY 0 2 o OIL LEVEL T i T BATTERY 0 8822 2 d 26 Vg RUNNING Ud on un 170 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START Spark Plug No Spark to Spark Plug Dealer Water in Fuel Fuel Valve Off Drain System Clogged Fuel Valve or filter 171 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER Engine Fouled Clean Radiator Overheated Turn Fuel Air Filter b screen and Valve to Res Clogged Radiator Core liquid cooled d
14. and all grease fittings 99 RIDING Trail Obstacles 100 RIDING Keep Alert Look ahead and learn to read the trail as you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches A WARNING Not all obstacles are visible Travel with caution on trails severe injury or death can result if your machine comes in contact with a hidden obstacle Indicates a potential hazard which could AWAR N NG result in severe injury or death 101 RIDING Parking on an Incline 102 RIDING Whenever the Vehicle is Parked 1 Turn the engine off 2 Set the parking brake 3 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above 4 Shut off fuel supply 103 PVT SYSTEM OPERATION PVT System A WARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the follow ing responsibilities to make sure this system remains safe Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of bal ance creating vibration and additional loads o
15. inspection checklist found on page 20 75 VEHICLE BREAK IN PERIOD After the break in period the oil injection system provides the necessary engine lubrication without the need for pre mixed fuel CAUTION Fill the oil tank when you refuel your ATV If you don t serious engine damage could result After the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see your dealer for oil pump bleeding and repeat the pre mix procedure 76 CARRYING LOADS The Sportsman 90 has been designed to carry a certain amount of load CARGO WEIGHT should be evenly distributed 1 3 on the front and 2 3 on the rear and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Never exceed the weights specified and never attempt to carry cargo on the Scrambler models A WARNING Correct loading of this vehicle is necessary to maintain proper stability and op erating characteristics Overloading or incorrect positioning of the load affects the vehicle s turning stopping distance and stability Failure to follow loading requirements could cause severe injury or death 77 CARRYING LOADS 2 3 of Load o Rear Rack 1 3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying load
16. parking brake whenever the vehicle is left unattended Before starting the engine make certain the park brake is fully locked Since the machine has a transmission that is always in forward throttle activation to warm the engine will make the machine go forward if the park brake is not locked Once the engine has warmed enough for operation release the park brake and gently apply the throttle to go forward 59 CONTROL AND PARTS FUNCTIONS A WARNING Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e Do not smoke or allow open flames or sparks in or near the area where re fueling is performed or where gasoline is stored e Do not over fill the tank Do not fill the tank neck e f you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing e Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time e Shut off fuel valve whenever the ATV is stored or parked CONTROL AND PARTS FUNCTIONS Indicates a potential hazard which AWAR N NG could result in severe injury or death Z WARNING The engine exhaust from this prod uct contains chemicals known to cause cancer birth defects or other reproduct
17. tip is black A damp oil film covers the firing end There may bea carbon layer over the entire nose Generally the electrodes are not worn Gener al causes are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments 143 MAINTENANCE Spark Plug Removal and Replacement A WARNING Never attempt to remove a spark plug while the engine is warm The exhaust system or engine could burn you causing severe injury The spark plug is removed by using the special wrench provided in the tool pouch Remove the spark plug cap and then the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17 ft Ibs Never deviate from the recommended spark plug as engine damage can occur 144 MAINTENANCE Cylinder Head Cylinder Base Fastener Torque 2 Cycle Models Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours Indicates a potential hazard which could AWAR N result in severe injury or death 145 MAINTENANCE Transmission Lubrication The transmission dipstick A is located on the top of the transmission The transmission lubricant level should be checked monthly Transmission oil should be changed annually With the ATV on a level surface remove fill plug dipstick and check the lubricant level Lubricant should be kept at the full mark o
18. your right wrist The other end must be attached to the ATV Always attach the tether strap before you ride Sportsman F and Scramblers G Never ride without the tether strap attached to your right wrist and machine Be careful not to get the cord tangled around the handlebars or any part of your body KNOW YOUR MACHINE Let s review the three ways to stop your ATV 1 Sliding the shut off switch to the left or right 2 Disconnecting the tether strap will shut off the engine 3 Turning the key to off will shut off the engine R 10 KNOW YOUR MACHINE PRE RIDE CHECK You are almost ready to have an adult start your ATV Before the ATV is started for the first time you must do a PRE RIDE CHECK In fact every time you ride your ATV you must have an adult help you check these things before starting it Let s learn about these things now Make sure the throttle doesn t stick Check this by pushing the lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays open you have a sticky throttle This means that something is wrong or broken If you have a sticky throttle do not start the engine You could get hurt if you ride when you have sticky throttle Have an adult or your Polaris Deal er fix the throttle PRE RIDE CHECK 4 sure the brakes don t stick Check the brake levers by squeezing
19. CTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT 7079133 GENERAL SAFETY AND DESCRIPTION OF LABELS Improper ATV use can result in SEVERE INJURY OR DEATH Always use an approved helmet and protective gear Never use on public roads Never carry passengers Never use with drugs or alcohol NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEAL ER FOR A REPLACEMENT GENERAL SAFETY AND DESCRIPTION OF LABELS Kids under age 6 should NEVER operate this ATV Kids under 6 have an increased chance 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 safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 de
20. GINE T BRAKE SWITCH ize ET i E w L n Eos om E 1 m zi aci P LOCATED AT LEFT Be ILI sf BRAKE Lo BATTERY CO exe STARTER e emt TAYE CAMP i ROTE ELAY 8 Sanit ep 05 BRN 1 7 BATTERY Ge AJ _ ep Y suites cose ow NS T miM DO sui won 169 WIRING DIAGRAM 2001 SPORTSMAN 90 E lon cioar VATI SWITCH pas MEET LEFT HAND STATOR RESISTE 2001 SCRAMBLER 90 SWITCH a op FRONT LIGHT MEN Z SWITCH 1o srar grad TET M Lie aa 0 HE Sarti Tute i aa C cuose eis Et Ex s 6 grex men Eh THROTTLE LI T RELEASED i ni ss ap Eod H 5 im 3 i f me Eg START
21. IONS Engine Throttle AWA R N e I oara A WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls A stuck or improperly operating throttle could cause an accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle system can re sult in the throttle lever sticking during riding and cause an accident Always check the lever for free movement and return before starting the en gine and occasionally during riding CONTROL AND PARTS FUNCTIONS Throttle Lever Engine speed and vehicle movement are con trolled by pressing the throttle lever The throttle lever 1 is spring loaded and engine speed returns to idle when the lever is re leased This vehicle is equipped with an Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle In the event the throttle cable should stick in an open position the engine will stop and power to the rear wheels will cease when the opera tor releases the throttle lever 54 CONTROL AND PARTS FUNCTIONS A WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not at tempt to modify the ETC system or replace it with any after market throttle mechanism
22. L FASTER THAN THE RECOMMENDED SPEEDS 80 DAILY PRE RIDE CHECK A WARNING You must inspect your ATV each time before riding to ensure it is in proper working order If proper check is not done severe injury or death could result 81 DAILY PRE RIDE CHECK Use the following checklist to verify your machine is in proper working order each time you ride Item Inspection Procedure Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper levels All brakes check operation and adjustment Throttle check for free operation and closing Brakelight check for proper operation Engine stop switch check for proper function o MN Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 82 DAILY PRE RIDE CHECK 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fas teners 12 Operators helmet goggles and clothing Indicates a potential hazard which could AWAR N G result in severe injury or death 83 RIDING 84 at OO N RIDING Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up
23. NG To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious injury or death Battery terminals and connections should be kept free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or pe troleum jelly Be careful not to allow cleaning solution or tap water into the battery 110 BATTERY Set the battery in its holder First connect and tighten the red positive cable Second connect and tighten the black negative cable Attach the hold down strap Verify that cables are properly routed NOTE e When your ATV is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool dry place OE EE E e Before reusing take the battery to your dealer for testing and recharging e When installing a new battery make certain it is fully charged prior to it s initial use Using a battery that is not fully charged can damage the battery resulting in a shorter life of the battery It can also hinder vehicle performance 111 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED U S Federal law proh
24. NTENANCE Tool Kits To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Items included in the kits are 2 cycle engines e spark plug wrench with Phillips head screwdriver e tire pressure gauge Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reli able condition Inspection adjustment and lubrication intervals of important com ponents are explained in the following chart on the following pages 115 MAINTENANCE Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently If you are not familiar with safe service and adjustment proce dures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Service and adjustments are critical If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations A CAUTION Due to the nature of the adjustments marked with a lil on the following chart it is recommended that service be performed by an authorized Polaris dealer 116 MAINTENANCE M
25. POLARIS 2001 YOUTH ATV MODELS Owner s Safety and Maintenance Manual Read this manual carefully It contains important safety information Scrambler 50 No one under the age of 6 should ride this vehicle Sportsman 90 and Scrambler 90 No one under the age of 12 should ride these vehicles AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm AWARNING Indicates a potential hazard which could result in severe injury or death A WARNING eo Never carry passengers Never use with Never use on public roads drugs or alcohol Always use an approved helmet and protective gear NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passen gers affect balance and steering and increagse risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handingl and control Improper ATV use can result in SEVERE INJURY or DEATH PCSLERIS The Way Out Part No 9916424 FOREWORD Congratulations and thank you from Polaris Industries Inc for purchasing one of our all terrain vehicles ATVs Built with American engineering and manufacturing know how it is designed to provide superio
26. RIDING RULES Don t ride your ATV on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you gt Don t ride at night Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them Never ride on frozen water You could get hurt or you could even die All ice can be dangerous p Always be alert and pay attention to where you are driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do RIDING RULES gt Never follow another ATV too closely Always allow lots of time and space to stop your ATV Only ride your ATV where you know it is safe to drive No driving over the flower garden or on the little trees you planted Be careful of the things around you p gt Always attach the tether strap to your right wrist and machine before riding Respect your ATV respect your environment and you will earn the respect of everyone R 20 UNDERSTANDING WARNINGS ATTENTION Always follow the age guidelines on the machine YOU MUST MAKE CERTAIN THE OPERATOR S UNDERSTAND ALL WARNINGS AND THE OWNER S MANUAL BEFORE OPERATION A KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING It is the parent s responsibility to teach their children the proper and safe way to ride any ATV This should be done by reading the owner s manual with your children be f
27. RIS KNOW YOUR MACHINE PARENTS Review the information in this manual with any child who may be operating the ATV It is up to you to teach your child the proper and safe way to ride an ATV You must set boundaries and adhere to them keeping your child s safety foremost in your mind Never allow your child to operate this machine without adult supervision CHILDREN Before you ride your new Polaris ATV there are some important things you should know How to keep safe is the most important thing You must also learn some things that will keep you and those around you safe while you are riding KNOW YOUR MACHINE Pay attention when you see this symbol This is the safety alert symbol When you see this symbol on your machine or in this manual it means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety is involved KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time let s learn about the controls on your new machine 1 Engine Stop Switch When the engine is running you can slide this button to the left or the right and the engine will stop The stop switch must be in the middle position to start the engine again 2 Throttle Control A This makes your ATV go forward when you press it with your thumb You must always make sure the throttle control does not stick before you operate your ATV Read more about it on page 12
28. TY AND DESCRIPTION OF LABELS 16 GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING Moving parts hazard under belt clutch guard prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death A WARNING A WARNING DO NOT TOW FROM RACK OR BUMPER DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result Vehicle damage or tipover may result causing severe injury or death causing severe injury or death Maximum Front Rack Load 10 Ibs Maximum Rear Rack Load 20 Ibs a 0 O z Found on the Sportsman 90 17 GENERAL SAFETY AND DESCRIPTION OF LABELS MANUFACTURED BY POLARIS IND INC THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS 18 10 A WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT2 REAR2 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 423 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unse cured loads will increase your risk of losing control Loads should be centere
29. aces Shift your weight to the uphill side of the ATV OPERATION WARNINGS A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismount ing while climbing a hill WHAT CAN HAPPEN Could result in ATV overturn ing V S HOW TO AVOID THE HAZARD LOG Maintain steady speed when climbing a hill MI If you lose all forward speed Keep weight uphill Ap ply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly by squeezing the RH lever When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure de scribed in the Owner s Manual See page 96 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to over turn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control Indicates a potential hazard which could AWAR N NG result in severe injury or death OPERATION WARNINGS A WARNING 40 POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Co
30. amiliarize yourself with their function and affect on the ATV Indicates a potential hazard which could AWAR N result in Severo injury or death TABLE OF CONTENTS RIDER S SECTION 2 bi aint taeda ee R 1 R 20 UNDERSTANDING WARNINGS eee rh 1 4 GENERAL SAFETY AND DESCRIPTION OF LABELS 5 18 DAILY PRE RIDE CHECK ek ek RR RA 20 21 OPERATION WARNINGS 22 46 VEHICLE IDENTIFICATION NUMBERS 47 48 CONTROL AND PARTS FUNCTIONS 49 69 STARTING THE ENGINE aod RR Re Ra Re 70 71 RIDING GEAR a a aA 72 73 VEHICLE BREAK IN PERIOD 00 0c cece eee 74 76 CARRYING LOADS a a x 77 80 DAILY PRE RIDE CHECK gt ae be wa em eb ee 81 83 RIDINGS Stee 84 103 TABLE OF CONTENTS PVT SYSTEM OPERATION 104 105 BATTERY ette epe re tede A edible tr dete rede 106 111 NOISE EMISSION CONTROL SYSTEM REGULATION 112 114 MAINTENANGE pan t ore coe e c ex ee Poe e qe 115 161 eye UE Re E atte 162 168 WIRING DIAGRAMS sssssseee eee eens 169 170 TROUBLE SHOOTING erai TARDE UM EM ERE TM UR 171 172 WARRANTY oi eR re emp RETE eee eam nera 173 178 INDEX CEDE 179 180 xi RIDER S SECTION POLA
31. and engine damage may occur 68 CONTROL AND PARTS FUNCTIONS Kick Starter If the battery is weak and cannot start the en gine kick start lever will allow vehicle opera tion until repairs can be made 1 Be certain your vehicle is on a level surface and the parking brake is set See page 58 2 Fold outthe kick start lever A which is onthe left hand side of the machine 3 Turn the key to ON and make sure the stop switch is in the RUN position 4 Placing your foot on the kick start push your heel downward to crank the engine 5 Once the engine has started fold the kickstart lever back into place 69 STARTING THE ENGINE Procedure for Starting a Cold Engine Indicates a potential hazard which could AWAR N G result in severe injury or death A WARNING Never run an engine in an enclosed area Carbon monoxide exhaust gas is poi sonous and can cause severe injury or death Always start engines outdoors CAUTION You must allow your vehicle adequate warm up time before operating or en gine damage could result 70 NO FP STARTING THE ENGINE Set the parking brake Turn the fuel tank valve to ON Sit on the vehicle Attach tether strap to machine and wrist Turn the engine stop switch to RUN Turn the ignition key to ON Press the starter button NOTE The rear brake lever must be engaged or the en gine will not start Do not press the t
32. ath in the event of an accident Operating without eye protection can result in an acci dent and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 27 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases your chances of losing control of the ATV which can result in an acci dent HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience Indicates a potential hazard which could AWAR N result in severe injury or death 28 ON S S OPERATION WARNINGS 4 WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies o
33. cations WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Polaris In dustries Inc or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized Polaris ATV dealer VEHICLE IDENTIFICATION NUMBERS 47 VEHICLE IDENTIFICATION NUMBERS Record these numbers from your ATV in the spaces provided 1 Engine Serial Number Left side of engine crankcase 2 Frame VIN found on the front of frame below steering post Remove the spare key and store in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essential to the recovery and identification of your ATV CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1 Main Switch Located on the Right hand side of the Scram blers A and on the p
34. ces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during op eration Itis not for carrying passengers 23 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces including side _ walks paths parking lots and driveways RORIS WHAT CAN HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever pos sible If you must ride on a paved surface go slowly and do not make sudden turns or stops OPERATION WARNINGS A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on public streets roads and highways 25 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and pro tective clothing WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or de
35. ched Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer Allow greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safe ty Commission at 1 800 638 2772 or Polaris at 1 800 342 3764 Additional Important Information Due to our concern for the safety of our customers and the general public Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any other modifications to the vehicle forthese purposes Any modi fications to the original equipment of the ATV substantially increase the risk of bodily injury Please be aware that these modifications may create a substantial safety haz ard viii Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power We also advise you to strictly follow the recommended maintenance program outlined in this manual This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals NOTE The addition of certain accessories may change the handling characteristics of the ATV Be certain any accessories added to this ATV have been approved by Polaris F
36. d carried as low as possible and firmly se cured to the racks With dual racks load distribution 1 3 front 2 8 rear is best For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information Found on Sportsman 90 OPERATION WARNINGS 4 WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 19 DAILY PRE RIDE INSPECTION A WARNING This ATV must be inspected each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result Use the following checklist to verify your machine is in proper working order each time you ride Item Inspection Procedure Tires check condition and pressures Fuel and oil tanks fill both tanks to their proper levels
37. d re move the filter B Soak the filter in a mild detergent and rinse it in clean water Let the filter air dry and reinstall in the air box MAINTENANCE 133 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts If loose nuts and bolts are found have your dealer tighten them before riding your vehicle Camber and Caster The camber and caster are non adjustable A WARNING Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your Polaris dealer He she has the training and tools to make these adjustments 134 Throttle Stop 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 travel To adjust loosen the jam nut D Turn the screw E inward to re duce speed and outward to in crease speed Tighten jam nut after adjusting MAINTENANCE 135 MAINTENANCE Toe Alignment You can check the toe alignment of the vehicle using the following method The recommended toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer correct it 1 the handlebars in a straight ahead position and hold them this position NOTE The stee
38. e Make sure operators follow Owner s Manual and labels Make sure operators watch the safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually GENERAL SAFETY AND DESCRIPTION OF LABELS 3 IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT2 REAR2 maximum weight capacity Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS LBS Found on Scrambler 50 and Scrambler 90 12 GENERAL SAFETY AND DESCRIPTION OF LABELS 4 WARNING NEVER ride as a passenge Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Indicates a potential hazard which could AWAR N result in severe injury or death 13 GENERAL SAFETY AND DESCRIPTION OF LABELS 14 GENERAL SAFETY AND DESCRIPTION OF LABELS e Operation of this ATTENTION Specific carburetor jetting vehicle without the and adjustments are filter element will severely required depending on temperature damage the engine and altitude See your Owner s Manual e Clean air filter often more Factory Setting frequent cleaning required in dusty conditions 40 to 80 at 0 3000 feet 5 to 27 C at 0 900 meters 6 on rear of seat NO PASSENGER PASSAGERS INTERDITS 15 GENERAL SAFE
39. e boots with heels such as moto cross boots 5 Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads a jersey and shoulder pads provide the best protection 73 VEHICLE BREAK IN PERIOD 2 Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient per formance and longer life for the engine Perform the following procedures careful ly CAUTION Use only Polaris injection oil Never substitute or mix oil brands Serious en gine damage and voiding of warranty can result 1 Mix 6 4 ounces of injection oil to two gallons of gasoline in a suitable gas can Fill the fuel tank as outlined on page 65 2 Fill the oil tank with Polaris injection oil 74 VEHICLE BREAK IN PERIOD 3 Drive slowly at first Select an area which is open and will give you room to familiar ize yourself with vehicle operation and handling CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and all important areas on the ve hicle as outlined earlier on the daily pre ride
40. ferently from other vehicles including motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use only if they determine that the child has the ability and maturity to operate the ATV safely ailure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH Read this manual and all labels carefully and follow the operating procedures de scribed Never operate an ATV without proper instruction Take a training course Riders should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342 3764 to find out about the training courses nearest you Always follow the age guidelines for your machine Youth ATVs are designed and intended for use by children in two age groups The Scrambler 50 is for children not less than 6 years of age The Scrambler 90 and the Sportsman 90 are for chil dren not less than 12 years of age No children under the age of 16 should ride an ATV designed and sold for an adult Do not allow other children to ride this ATV unless they have read the manual seen the instructional video and
41. gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 7 3 ft Ibs NOTE Tighten bolts so there is an equal gap at the front and rear of the handlebar block Improper gap will re sult in improper fit of upper pod MAINTENANCE 129 MAINTENANCE The following items should be checked occasionally for tightness or if they have been loosened for maintenance service Axle and Wheel Nut Torque Specifications Front Spindle Nuts 43 ft Ibs Rear Spindle Nuts 80 ft Ibs NOTE All nuts that have a cotter pin installed must be serviced by an autho rized Polaris Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op erations Service work must be performed by your authorized Polaris dealer 130 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is ad justed by rotating the adjuster in the direction required to increase or decrease Rear Spring spring tension Adjustment 131 MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation If the vehicle is rid den in wet or dusty conditions clean the filter more often CAUTION Never operate the ATV with the filter element removed Dirt will enter the engine causing serious rapid wear and damage to the engine 132 To clean the filter Td Remove the screws on the airbox A an
42. grees 15 To prevent flipover on hilly terrain use throttle and brakes gradually Found on Scrambler 50 SAFETY WARNING AND OPERATION DECALS Kids under age 6 should NEVER operate this ATV Kids under 6 have an increased chance 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 safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually SAFETY WARNING AND OPERATION DECALS 10 Kids under age 12 should NEVER operate this ATV Kids under 12 have an increased chance 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 safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually 7079091 GENERAL SAFETY AND DESCRIPTION OF LABELS e Kids under age 12 should NEVER operate this ATV Kids under 12 have an increased chance of losing control which could result in severe injury or death Adult supervision is required
43. hours More often under severe use such as wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Grease every 40 hours or approximately 500 miles or after submerging in water or before long periods of storage or after pressure washing Always use Polaris Premium U Joint Lube for maximum service of these driveline components PN 2871515 3 oz PN 2871551 14 oz When suspension action becomes stiff or after washing 124 MAINTENANCE NOTE Hours are based on 10 mph average MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed MAINTENANCE Maintenance Servicing Servicing Interval Date Dealer Performed or Person MAINTENANCE A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handle bars resulting in loss of control and possible serious personal injury or death Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit 1 Locate handlebar bolts On models with a headlight pod it will be necessary to remove the upper headlight pod On other models remove the handlebar cover 128 2 Loosen the four bolts 3 Adjust handlebar to desired height Be sure handlebars do not hit
44. hrottle while starting the engine Activate the starter for a maximum of five seconds releasing the button when the vehicle starts If engine does not start release the starter and wait five seconds then activate the starter for another five seconds Repeat this procedure until en gine starts After the engine starts vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly 71 RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury 1 Helmet Your helmet is the most important piece of protec tive gear for safe riding A helmet can prevent a severe head injury Select an approved helmet which meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI 290 1 or the Snell Memorial Foundation label 72 RIDING GEAR 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or hel met face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf typ
45. ht for ward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another ve hicle or person could be on the other side of the hill OPERATION WARNINGS A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described i in ee s Manual See page 94 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible OPERATION WARNINGS 4 WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 96 Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surf
46. ibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise control prior to its sale or deliv ery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been re moved or rendered inoperative by any person ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BE LOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 112 NOISE EMISSION CONTROL SYSTEM REGULATION 2 Removal or alteration or the puncturing of any part of the engine air induction sys tem 3 Replacement of any vehicle parts with parts not in compliance with federal regula tions 4 Lack of proper maintenance CAUTION Remember exhaust system components are very hot during and after use of ATV e Do not touch exhaust system components Serious burns can result e Be especially careful when traveling through tall grass The potential for fire ex ists 113 NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100 14 114 MAI
47. id by turning the handlebars in the direction of the skid and shifting your body weight forward Never apply brakes during a skid Complete loss of ATV control can result Do not operate on excessively slippery surfaces if possible to avoid Always reduce speed and use additional caution AWARNING Failure to exercise care when operating the ATV on slippery surfaces can be dangerous Loss of tire traction and vehicle control can result in an accident including an overturn 89 RIDING Traveling Uphill 90 RIDING A WARNING Do not operate this machine on hilly terrain If you cannot avoid operating in hilly terrain use extreme caution Braking and handling are greatly affected Loss of vehicle control or overturning of the ATV could occur causing severe injury or death If you have to travel uphill always travel straight uphill and 1 a BR C Avoid steep hills 15 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV 91 RIDING Sidehilling 92 RIDING Avoid traveling across the side of a hill at all costs In the event you do enter into a situation where sidehilling is unavoidable always 1 Slow down 2 Lean into the hill transferring your upper body weight up hill while keepi
48. ightening jam nuts or the stud may break 154 MAINTENANCE Rear Drive Chain Slack Adjustment CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result The normal chain slack should be kept between 40 80 10 20 mm A 155 MAINTENANCE Adjustment Procedure 1 Loosen 4 rear housing mount bolts A 2 Tighten chain adjuster B to reduce slack to recommended setting 4 8 10 mm 20 mm 3 Tighten jam nuts on chain adjuster 4 the four rear housing mount olts 156 Brakelight Lamp Replacement If the brakelight does not work the lamp may need to be replaced 1 From the rear of the brake light remove two screws A holding lens cover in place and remove lens cover B 2 Remove lamp C and replace it with recom mended lamp 3 Test the brakelight to see that it s working 4 Reinstall the lens cover removed in step 1 MAINTENANCE 157 MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also ex tend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels Man
49. ing brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine release parking brake and proceed slowly controlling speed with the service brake until ATV is on reasonably level ground O A WARNING Avoid climbing steep hills Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death 97 RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the foot rests Before fording streams always 98 RIDING Determine water depths and current Choose a crossing where both banks have gradual inclines Proceed slowly avoiding rocks and obstacles if possible After crossing dry the brakes by applying light pressure to the levers until braking action is normal If you do not perform this procedure your brakes may be ineffec tive RON e Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements maintain a slow and steady for ward motion Do not make sudden turns or stops and do not make sudden throttle changes NOTE If the vehicle is run in water it is critical the machine is serviced as out lined in the maintenance chart beginning on page 117 The following areas need special attention engine oil transmission oil front and rear gearcases
50. ion RES For reserve supply in the event of main supply exhaustion Sportsman NOTE There is about a 7 to 10 mile 11 2 Fuel Valve to 16 km range on reserve gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to on position after refueling machine 64 CONTROL AND PARTS FUNCTIONS Engine Fuel Safety Fuel Filter The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter CAUTION Use only Polaris injection oil Never substitute or mix oil brands Serious en gine damage and voiding of warranty can result To avoid serious engine damage always top off the oil level when refueling 65 CONTROL AND PARTS FUNCTIONS Oil System The oil tank 1 is located under the seat and has a capacity of 12 ounces 1 liter To remove the seat reach under the rear of the cab and pull back on the seat latch To re place the seat set it in place and push down on the rear of seat Always make sure the seat is locked in place before riding A CAUTION Do not attempt to release the seat latch unless the machine has not been run for at least an hour The exhaust gets very hot when the machine is run and can cause serious burns 66 CONTROL AND PARTS FUNCTIONS CAUTION Engine warranty coverage may beco
51. is dealer if it has been involved in an accident Never operate the ATV on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills vi Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for braking on hills as de scribed in this manual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground Avoid crossing the side of a steep hill if possible Always use proper procedures if you stall or backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backward
52. ive harm 61 CONTROL AND PARTS FUNCTIONS PVT System AWARNING The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the fol lowing responsibilities to make sure this system remains safe Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of bal ance creating vibration and additional loads on components e Routine maintenance is the responsibility of the owner Always follow rec ommended maintenance procedures See your dealer e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap 1 is located directly behind the handlebar The tank has a ca pacity of 1 3 gallons 5 liters Use un leaded gasoline with a minimum pump oc tane number of 87 octane CONTROL AND PARTS FUNCTIONS The fuel valve is located on the engine be hind the right front fender and has three positions OFF For vehicle storage and whenever transporting ON For normal operat
53. ler immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 174 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control 175 WARRANTY This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warran ty shall be at Polaris exclusive option repair or replacement of any defective materi a
54. ls or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 176 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR POSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PE RIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you musttake itto a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any P
55. me void if you use a brand other than Polaris in your machine Polaris 2 Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use The only oils recommended for Polaris 2 cycle ATVs are Po laris Premium 2 cycle oil or Premium Gold Synthetic 2 cycle oil 67 CONTROL AND PARTS FUNCTIONS Polaris Premium 2 cycle lubricants are the most advanced formulation of oils spe cifically designed for today s 2 cycle engines Months of lab and field tests have resulted in a new generation of 2 cycle lubricants Polaris Premium 2 cycle lubri cants provide additives for 2 cycle engines lacking in today s fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanli ness With new generation lubricity technology they excel in meeting the lubrica tion demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are the best available in the market today Premium 2 Cycle Polaris also has a TC W3 premium oil available for use in all of our 2 cycle prod ucts We highly recommend its use if premium gold synthetic is not used The only oil recommended for this ATV is Polaris brand oil Polaris Premium 2 cycle oils will readily mix with each other however do not mix Polaris Premium 2 cycle oils with any other oils as they may not be compatible
56. mproper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires on this ATV or operation of this ATV with improper or un even tire pressure may cause loss of control and increases the risk of an acci dent HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual Supplement for this vehicle maintain proper tire pressure as described in the Owner s Manual Sup plement 43 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Overloading this ATV 44 WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached OPERATION WARNINGS WARNING After a rollover or an accident have a qualified service dealer check the plete machine including but not limited to brakes throttle and steering for possible damage A WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death Indicates a potential hazard which could AWAR N result severe injury or death 45 OPERATION WARNINGS A WARNING 46 POTENTIAL HAZARD Operating this ATV with improper modifi
57. n ad justments can be made to improve its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 396 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained changes to the carburetor and drive sys tem can be made to allow efficient operation These changes include 1 Carburetor re jetting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss during high altitude operation Contact your dealer 3 On2 cycle models air screw adjustments can be made to compensate for temper ature changes and or changes in altitude NOTE Contact your dealer for altitude adjustments They have the training and special tools required to perform all necessary modifications for you 161 SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension 162 Specifications Scrambler 50 A Arm with 2 5 cm of travel Spring over shock with 2 5 cm of travel SPECIFICATIONS Specifications Scrambler 50 Front and Rear Tires PSI 6 138 7 Dy Weight Lengih i Heg Low Oi Lg 163 SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission
58. n components e Routine maintenance is the responsibility of the owner Always follow rec ommended maintenance procedures See your dealer e This PVT system is intended for use on Polaris products only e The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or re M PVT SYSTEM OPERATION If the vehicle is operated in dusty areas it will be necessary to clean the filter more often To clean the PVT filter 1 Remove the screws and the crankcase cover 2 Remove the screws and the filter cover 3 Soak the filter in a mild detergent and rinse with clean water 4 Allow the filter to air dry and reinstall it CAUTION If your vehicle is operated in salt water areas it must be rinsed with fresh water to prevent corrosion that can be caused by exposure to seawater 105 Battery A WARNING Only adults should ever touch the battery Never allow children to handle a battery or service a battery in any way A WARNING Whenever removing the battery disconnect the negative black cable first When reinstalling the battery connect the negative black cable last or an explosive situation could result causing serious injury or death 106 A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water
59. n the dipstick The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubri cant PN 2871478 146 MAINTENANCE Transmission Oil Changing Procedure 1 2 3 4 Remove fill plug dipstick Remove transmission drain plug and drain the oil Catch and discard used oil prop erly Clean and reinstall the drain plug Add Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle to full mark on the fill plug dipstick Check for leaks 147 MAINTENANCE A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death Follow the safeguards listed below to prevent this type of situation 148 MAINTENANCE Important Safeguards Maintain proper tire pressure according to charts below Improper tire inflation may affect ATV maneuverability Do not use improper tires The use of non standard size or type tires may affect ATV handling Make certain the wheels are installed properly If wheels are improperly installed it could affect vehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel
60. nded that service be performed by an authorized Polaris dealer gt More often under severe use such as dirty or wet conditions Item Hours When Remarks or Miles m Spark Plug 100 hrs 12 months Inspect replace if necessary I Ignition Timing 100 hrs 12 months Inspect and adjust as needed 120 MAINTENANCE LUE Fuel System 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor Re place lines every two years W Fuel Filter 100 hrs 12 months Replace annually Spark arrestor 100 hrs 12 months Clean out out Front wheel bear 300 hrs 36 months Inspect replace ings Idle Speed As Re As Re Adjust quired quired Toe adjustment As re As re Periodic inspection adjust when parts quired quired are replaced 121 MAINTENANCE Lubrication Recommendations em Weho Frequency 1 Engine Oil Polaris Fill oil tank See page 63 As needed Injection Oil when refueling 2 Transmission Oil Polaris Premium See Page 146 Change annually Synthetic gear or at 100 hours case lube 122 MAINTENANCE Lubrication Recommendations 2 Transmission plug Operating Range 123 MAINTENANCE 3 Drive Chain O Ring chain lube Lubricate as often as re As required SAE 80 90 quired Before each ride in wet conditions 4 Front A Arm Grease Locate fittings and grease Every 3 months or 50
61. ng your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dis mount on the uphill side immediately A WARNING Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the ATV could occur causing severe injury or death 93 RIDING Traveling Downhill 94 RIDING Whenever descending a hill always 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the the front and rear brakes atthe same time and very slightly to aid in slow ing A WARNING Do not travel at excessive speeds It is dangerous and can cause loss of ve hicle control and tipping resulting in severe injury or death 95 RIDING Turning Around On A Hill If the ATV stalls while climbing a hill never back it down the hill One maneuver which can be used when it is necessary to turn around while climbing a hill is the K turn 96 RIDING Stop and lock the parking brake while maintaining body weight uphill Shut off engine Dismount on left or uphill side of ATV Staying uphill of ATV turn handlebars full left while facing front of ATV While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward Lock the park
62. nuts and remove the wheel 149 MAINTENANCE Wheel Nut Torque Scrambler 50 Front 16x8 7 22 ft Ibs me feer aes 150 MAINTENANCE Wheel Installation 1 With the park brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and finger tight en them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts ac cording to the chart found on page 130 151 MAINTENANCE Tire Inspection When replacing a tire always use original equip ment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm 1 or less 152 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O ring sealed permanently greased pins and rollers However it is still necessary to lubricate the outer surfaces of the roller CAUTION Never wash the chain with a high pressure washer or gasoline Damage to the O rings will result causing premature wear and drive chain failure Regularly lubricate the drive chain with SAE 80 90 lube or an approved O ring chain spray lube Indicates a potential hazard which could A WAR N result in severe injury or death 153 MAINTENANCE Drive Chain Inspection and Adjustment Cont CAUTION The adjuster stud must be held secure when t
63. od of the Sportsman B This switch is operated with a key and must be turned clock wise to the position to start the engine 49 CONTROL AND PARTS FUNCTIONS 2 Emergency Engine Stop Switch The engine will not start or run when the switch is in its off position Its purpose 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 the emergency engine stop switch shut off all electrical power to the entire vehicle To stop the engine slide the stop switch right or left to the off position OFF RUN 50 CONTROL AND PARTS FUNCTIONS 3 Engine Start Button To start the engine make certain the tether switch is securely plugged into the machine and attached to the rider s right wrist Turn the key to the position set the parking brake and push the start button NOTE Remember to release the park brake before driving forward 51 CONTROL AND PARTS FUNCTIONS 52 CAUTION Engine or driveline damage could occur if the machine is driven without the park brake released A WARNING This ATV is not equipped with lighting This ATV is designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility Do not operate this machine after dark CONTROL AND PARTS FUNCT
64. olaris Servicing Deal er to perform warranty service 177 WARRANTY Please work with your dealer to resolve any warranty issues Should your dealer re quire any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Always use Polaris engine oil 2 Never substitute or mix oil brands as serious engine damage and voiding of warran ty can result 178 AIR CLEANER 132 BATTERY INSTALLATION 110 BATTERY MAINTENANCE 106 BATTERY REMOVAL 109 Brake 138 Brake Freeplay Adjustment 140 Brake Eever ceret ee wx R7 BRAKE PARKING 58 Brakelight Lamp Replacement 157 BRAKES FRONT 57 BRAKES REAR 57 Break In 74 76 CAMBER AND CASTER 134 CARBURETOR ADJUSTMENTS 161 CARRYING LOADS 77 80 Chain Adjustment 155 CLEANING YOUR ATV 158 Control and Parts Functions 49 69 CROSSING STREAMS 98 CYLINDER HEAD TORQUE
65. ore often under severe use such as dirty or wet conditions Brake System Pre ride inspection item Inspect daily pre ride inspection item Frame nuts bolts Pre ride Pre ride Pre ride inspection item fasteners Oil Level Daily Check when refueling Air Filter Inspect Clean Brake pad wear 10 Monthly Inspect periodically hrs 100 miles Monthly Check Terminals clean check fluid level MAINTENANCE Periodic Maintenance Schedule Cont A CAUTION Due to the nature of the adjustments marked with a on the following chart it is recommended that service be performed by an authorized Polaris dealer gt More often under severe use such as dirty or wet conditions Item Hours When Remarks or Miles Oil Pump Cable 5Ohrs 6 months Inspect adjust lubricate replace if re quired Carburetor Float Drain bowl periodically and prior to storage Bowl 118 MAINTENANCE Item Hours When Remarks ince Inspect adjust lubricate replace if neces ETC Switch sary pre ride inspection item gt Steering sons e monts inspect aiy bids gt RearAde sys 6 montns inspect bearngs Front Su penao inspect lubricate tighten fasteners Posee me ors inspect daily adjust and lubricate if need Clutches drive 100 hrs 12 Inspect clean and deed months 119 MAINTENANCE A CAUTION Due to the nature of the adjustments marked with a on the following chart it is recomme
66. ore they first use the ATV and periodically afterwards A SAFETY TRAINING When you purchased this vehicle your dealer presented a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed material and a video which instructs operators on safe operating procedures UNDERSTANDING WARNINGS You should review this information with your child on a regular basis In the event you purchased a used Polaris ATV from a party other than a Polaris dealer safety training can obtained at no charge from any authorized Polaris dealer Failure to follow the warnings contained in this manual can result in severe INJURY OR DEATH NOTE Illustrations used in this manual are for general representation only Your model may differ SAFETY ALERT WARNINGS identify special instructions or procedures which if not correctly followed could result in personal injury or loss of life Read all WARNINGS in this manual carefully Always follow their instructions UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages This is the safety alert symbol When you see this symbol on a your machine or in this manual be alert to the potential for personal injury Your safety is involved Indicates a potential hazard which could AWAR N G result in severe injury or death UNDERSTANDING WARNINGS The following precautiona
67. r jumps x Don t try to show off 29 OPERATION WARNINGS A WARNING 30 POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual OPERATION WARNINGS A WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation 31 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be aler
68. r riding comfort enjoyment and safety This manual is furnished to ensure that the operator and parents are aware of safe operating procedures It also includes information about the general care and tenance of your ATV Carefully read the following pages If you have any questions regarding this ATV con tact a Polaris dealer for assistance Remember Polaris dealers have the knowledge and facilities to provide you with the best service possible PROTECT YOUR SPORT Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended maintenance program as out lined This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals All information in this manual is based upon the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Illustrations included in this manual are general representations of parts having a similar function Your model may differ INTRODUCTORY SAFETY MESSAGE PARENTS AN ATV IS A TOY AND BE HAZARDOUS TO OPERATE ATV handles dif
69. ring frog can be used as an indicator of whether the handle bars are straight The frog should al ways point straight back from the steering post amp ese 220901 07202 ACER Q o 23 SOS ly 136 MAINTENANCE Toe Alignment cont 2 Place stands in front of the machine perpendicular to the rear tires 3 Tie an elastic string around the stands making sure string just touches side surface ofthe reartires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of front rim Rear rim measure ment should be 1 16 1 8 2 to 3 cm more than front rim measurement 5 If this measurement needs to be adjusted contact your dealer for service 137 MAINTENANCE Brake Adjustment Periodically check the freeplay of the front and rear brakes Refer to the chart below for the acceptable range of free play for your machine To adjust the front brake turn the adjust ment knob A until the freeplay is accept able 138 MAINTENANCE To adjust the rear brake turn the adjuster nut B until the proper freeplay is at tained 139 MAINTENANCE Brake Freeplay Adjustment Sportsman 90 39 78 39 78 10 mm 20 mm 10 mm 20 mm Scrambler 90 39 78 39 78 10 mm 20 mm
70. ry signal words are used throughout this manual to convey the following messages ACAUTI O N Indicates a potential hazard which may result in minor personal injury or damage to the ATV CAUTION Indicates a situation that can result in damage to the machine GENERAL SAFETY AND DESCRIPTION OF LABELS NOTE Warning decals have been placed on the vehicle for the protection of the operator s Read and follow the instructions on each decal carefully In the event any decal be comes illegible or comes off contact your Polaris dealer for a replacement Any safe ty decal needing replacement will be provided by Polaris at no charge The part num ber is printed on the decal GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ONPUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and Steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRU
71. s follow the special procedure for braking described in this manual Dis mount on the uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt to oper ate over large obstacles such as large rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth pg 98 go slowly bal ance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sud den throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry out the pads vii Always use the size and type tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use of accessories Never exceed the stated load capacity for an ATV Cargo should be properly distrib uted and securely atta
72. s read and follow the warnings listed below e REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO e CARGO WEIGHT DISTRIBUTION should be 1 8 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle tip over 78 CARRYING LOADS e HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations which may require backing downhill e ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unse cured loads can create unstable operating conditions which could result in loss of control of the vehicle e LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the ve hicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions e OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads which cannot be centered securely fasten load and operate with extra caution 79 CARRYING LOADS e EXTREME CAUTION MUST BE USED when operating with loads extend ing over the rack sides Stability and maneuverability may be adversely affected causing the machine to overturn e DO NOT TRAVE
73. t to changing terrain conditions when operating the ATV 32 OPERATION WARNINGS A WARNING POTENTIAL HAZARD Failure to use extra care when operating on Aa Re As excessively rough slippery or loose terrain lt lt SY Ss 1 WHAT 2 Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain 33 OPERATION WARNINGS 4 WARNING 34 POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN ATV could go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner s Manual See page 86 Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed OPERATION WARNINGS 4 WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Could cause loss of control or cause ATV to over turn HOW TO AVOID THE HAZARD Cond Always follow proper procedures for climbing hills as described in the Owner s Manual See pages 91 through 96 Always check the terrain carefully before you start up any hill d climb hills with excessively slippery or loose surfaces Shift your weig
74. taken and passed a Polaris approved riding skill test Always avoid operating an ATV on any paved surfaces including sidewalks drive Ways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never operate at excessive speeds Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow the inspection and maintenance procedures and sched ules described in this manual Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation Always go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do notturn at ex cessive speed Always have the ATV checked by an authorized Polar
75. uld cause loss of control or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual OPERATION WARNINGS WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water 41 OPERATION WARNINGS 42 4 WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fastflowing water If you canot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes See page 98 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let fric tion dry out the pads OPERATION WARNINGS A WARNING POTENTIAL HAZARD Operating this ATV with i
76. with you is your teacher You must listen and pay attention or you won t be safe when you ride Remember that safety while you ride is the most important thing Let s learn how to ride You must always follow the safe riding rules found on the next pages If you do not you could be hurt really bad or even killed gt Your ATV is made for one person Never carry a passenger A passenger will make the ATV harder to drive You may lose control and hurt yourself and your passenger gt Make sure you know where you are going to drive when your ATV is started Make sure the area is safe all around your ATV R 16 RIDING RULES p gt Always wear the right kind of clothing when you are riding your ATV You will need a good helmet with a face shield or goggles Wear a long sleeved shirt or jacket gloves long pants and boots Make sure your clothing fits properly If itis too small it could keep you from moving easily If it is too big it could hang down and get caught in a moving part RIDING RULES You must always follow the safe riding rules found on the next pages If you do not you could be hurt really bad or even killed p gt Never ride alone An adult should always be watching you in case you need help Always drive within the sight of an adult p gt Never ride on public trails Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the running boards
77. y expensive repair bills can result from using high pressure detergent systems NOTE high pressure car wash is used grease all zerk fittings immediately after washing Also run the vehicle to evaporate any water that might have en tered the engine or exhaust system 158 MAINTENANCE The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a professional type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your a Polaris dealer for free replacement Waxing Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the finish CAUTION Certain products including insect repellants and chemicals will damage plas tic surfaces Care must be taken when using these products near plastic sur faces 159 MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken 1 Turn the fuel valve to off 2 Be certain the fuel cap oil cap and seat are installed correctly 3 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope 4 Always lock the parking brake 160 MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures certai

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