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Polaris 9921483 Offroad Vehicle User Manual

1. 4 Kick Start Lever Know Your ATV 6 Gas Cap The gas cap has to be taken off when an adult puts gas in your ATV Never take the gas cap off Always make sure it s tightly closed Always have an adult put gas in your A ATV Never try to do it yourself 7 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the seat To replace the seat set it in place and push down on the seat above the latch Always make sure the seat is locked in place before riding 7 Seat Latch 21 Know Your ATV 8 Brake Levers Squeeze the brake levers toward the handlebar to slow down or stop the ATV The left lever controls the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and A be seriously injured Always take your thumb off the throttle lever when you squeeze the brake levers 8 Rear Brakes 8 Front Brakes 22 Know Your ATV 9 Ignition Switch The ignition switch key must be turned on before pushing the starter button You can also use this key to turn off the engine 10 Tether Strap and Switch The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will
2. Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill 104 Parking on a Hill or Incline Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown in the illus tration 4 Turn the fuel valve off Driving Safely 105 Driving Safely Driving Through Water Your ATV can safely operate through shallow water The recommended maximum depth for your ATV is below the bottom of the footrests Follow these procedures when operating through water 1 Determine water depths before driving through 2 water 2 Ifcrossing a stream choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes may be ineffective 106 Driving Safely Driving Through Water Avoid operating your ATV through deep or fast flowing water If the ATV is operated in deeper water than recommended it s critical to have it serviced as outlined in the mainte nance chart beginning on page 114 The following areas need special attention engine oil gearcase oil front a
3. whichever comes first See Hours Calendar Miles Km Page gt Wiring 100 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connec tors subjected to water mud etc E Clutches drive and driven 100 12M 1000 1600 Inspect clean replace worn parts E Front wheel bearings 100 12M 1000 1600 Inspect replace as needed Spark arrestor 300 36 M 3000 4800 Clean out 138 E Toe adjustment Inspect periodically adjust when 150 parts are replaced 121 Maintenance Lubrication Guide Item Lube Method Engine Oil Polaris Synthetic Youth Oil or Synthetic SAE 40 See page 124 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 130 Drive Chain Polaris Chain Lube or SAE 80 90 See page 153 gt Front Suspension A Arm Polaris All Season Premium Grease or grease conforming to NLGI No 2 Inspect tighten fasteners grease also after washing ATV or driving in water gt Perform these procedures more often for vehicles subjected to severe use 122 Maintenance Lubrication Guide Grease Points Grease Points 123 Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114 Oil may need to be changed more frequently if Polaris oil is not used Do not use
4. 142 143 Start Button 00 69 Starting the Engine 88 90 Steering Inspection 152 Stop Switch 0 68 Stopping the ATV 24 Stopping the Engine 91 Storages 5 cage aec denne E 173 176 203 Index S T V Switches Tail Lights oo 22 icig shaw dgelenk 163 Vehicle Identification Numbers 66 Engine Start Button 69 Tether Strap 00 23 Vehicle Immersion 134 135 Engine Stop Switch 19 68 EPO ess eorna ee 70 Horn Button 19 Throttle Cable Adjustment 144 WwW Ignition Switch 23 Throttle Control 19 Warranty 0005 196 197 Main Key Switch 67 Throttle Lever n n nonan 71 Warranty Emissions 196 197 Tether Switch 23 Throttle Stop Speed Control System Washing the ATV 170 143 Wheel Hub Tightening 162 Tire Pressure Warning Wheel Installation 161 Outlaw 90 37 Wheel Nuts 0 162 Sportsman 90 38 Wheel Removal 160 Tire Tread Depth 160 TIMES a ate at Ake o LAK 159 Toe Alignment 150 151 Transmission Oil 130 131 Transporting the ATV 177 Turning Around ona Hill 102 103 204
5. 2 Avoid steep hills 15 maximum 3 Keep both feet on the footrests 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle Driving Safely 15 Maximum 99 Driving Safely Driving Across Hillsides A WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual 100 Driving Safely Driving Across Hillsides Sidehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep ing your feet on the footrests 3 Steer slightly into the hill to maintain direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immedi ately 101 Driving Safely Turning Around on a Hill A WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on h
6. Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 190 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 war ranty 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 war ranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery mate rial corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control 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 warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WAR RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUE
7. always connect the negative black cable last 166 Maintenance Battery Battery Removal 1 2 3 4 Disconnect the hold down straps securing the electrical box and battery in position Disconnect the black negative battery cable first Disconnect the red positive battery cable next Lift the battery out of the ATV 167 Maintenance Battery Battery Installation and Connections Set the battery in its holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Attach the hold down strap Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge AR WN 168 Maintenance Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components CAUTION High water pressure may damage components Polaris recommends wash
8. cables etc HE Valve clearance 50 3M 500 800 Check clearance see your dealer for adjustments Carburetor float bowl 50 6M 500 800 Drain bowl periodically and prior to storage HE Throttle cable ETC switch 50 6M 500 800 Inspect adjust lubricate replace if necessary HE Choke cable 50 6M 500 800 Inspect adjust lubricate replace if necessary Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first oo Hours Calendar Miles Km age E Carburetor air intake 50 6M 500 800 Check for proper sealing air leaks ducts flange E Drive belt 50 6M 500 800 See your Polaris dealer gt E Brake pad wear 50 6M 500 800 See your Polaris dealer HE Fuel system 100 12M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years HE Fuel filter 100 12M 1000 1600 Change filter 129 gt Engine mounts 100 12M 1000 1600 Inspect Exhaust muffler pipe 100 12M 1000 1600 Inspect m Ignition timing 100 12M 1000 1600 Inspect gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service E Have an authorized Polaris dealer perform these services 120 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks
9. or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in the Owner s Manual See page 102 60 Driver Warnings A WARNING A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual 61 Driver Warnings A WARNING A 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 62 POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV
10. 146 147 Brake Adjustment Rear 148 Brake Freeplay 145 148 Brake Freeplay Specifications 145 Brake Lever Travel 149 Brake Levers 204 22 Brake Parking 75 76 Brakes oishan dna ad ote 74 76 Break in Period 83 84 202 Cc Camber and Caster 152 Carburetor 140 141 Choke Lever 0 68 Cleaning i3 cause keeh be as 169 Clothing san seule heed Salas 93 Clutch Cover Warning 41 Constant Variable Transmission 136 CVT Drying 137 CVT System 136 Cylinder Head Torque 134 D Daytime Running Lights 165 Drive Chain 153 Drive Chain Slack 154 Drive Chain Slack Adjustment 155 Driving Across Hillsides 100 101 Driving Downhill 104 Driving in Reverse 109 Driving on Slippery Surfaces 96 97 Driving Over Obstacles 108 Driving Procedure 94 Driving Through Water 106 107 Driving Uphill 98 99 E Electronic Throttle Control 71 Emission Control Systems 112 113 Engine Start Button 69 Engine Stop Switch 68 Equipment Modifications 15 Eye Protection 93 F Fuel Filtet reau oa oy Steak i 129 Fuel Stabilizer 174 Fuel System 78 80 Fuel Valve eei estate cases 81 G Gas Caproni nE AS ai 21 80 Gearcas
11. 2 Place stands in front of the vehicle perpendicular to the rear tires 150 Toe Alignment 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear mea surement should be 1 16 1 8 2 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service Maintenance OR P0280 ATUR tgn GOS gh gh gh SCoT ate Ovo G K FIN a Measure to rim oos 2 lt i TS mmm Stands 151 Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts If any are found have your dealer tighten them before operating the ATV Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counter clockwise to make adjustments 152 Maintenance Drive Chain Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the gen eral lubrication interval specified in the Periodic Maintenance Chart beginning on page 114 Lubricate more
12. Never ride on frozen water You could get hurt or you could even die All ice can be dan gerous Ride your ATV only where you know it is safe to drive and where you have permission to drive Be careful of the things around you Always be a polite driver Don t drive through the flower garden or over the little trees you planted Always do your best to help take care of nature 31 32 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new Polaris ATV Safety Decals Warning decals have been placed on the ATV for your protection Read and follow the instructions on each decal carefully If any of the decals shown in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part num ber is printed on the decal 34 Safety Decals Operation Warning WARNING 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 passeng
13. Read and follow all of the instructions for hauling cargo on the following pages Never carry cargo on the Outlaw 90 A WARNING Hauling cargo improperly can may cause loss of control and result in serious injury or death Always carry cargo as instructed in safety decals and in the owner s manual e Place 1 3 of the cargo weight on the front rack and 2 3 on the rear rack Carrying loads on only one rack increases the chance of a tipover Slow down Allow more space for stopping the ATV when hauling cargo 110 Driving Safely Hauling Cargo Never exceed the weight capacities for the vehicle Capacities are listed in the specifica tions section beginning on page 178 Secure all cargo before driving Loose cargo may move or shift which could cause loss of control or a tipover Use suitable tie downs or rope to secure the cargo Do not allow cargo or tie straps to hang over the edges of the racks Carry only small loads that fit on the racks Tall loads raise the center of gravity of the vehicle and may cause loss of control or a tipover Never allow a person to ride on the racks Never tow or pull an object behind the ATV A wagon sled or other object towed behind an ATV does not have brakes or steering The object may overturn or collide with other objects and cause serious injuries 111 Emission Control Systems Noise Emission Control System Do not modify the engine intake or exhaust components as
14. This limited warranty also does not cover physical damage corrosion or defects caused by fire explo sions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris War ranty Department at 1 888 704 5290 197 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 10 Hours Break in 40 Hours 50 Hours 80 Hours 198 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours 199 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 200 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 201 Index A ACCESSOTICS p dria ee 177 Age Warning 36 Air Filter l nonnene 156 157 Axle and Wheel Nuts 162 B Battery Installation Connections 168 Removal 167 Storage 0 168 173 Boots 62 3 5 5ote ayes Peis aces tig N 93 Brake Adjustment Front
15. air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer 189 Warranty LIMITED WARRANTY Polaris Sales 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 warranty 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 transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGIS TERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important in ensuring trouble free operation
16. distributed and securely attached 64 tions WHAT CAN HAPPEN Improper installation of accessories or modifi cation of the ATV may cause changes in han dling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions Driver Warnings A WARNING 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 Do not allow disabled persons to operate this vehicle A WARNING Hot components can cause serious burns Do not touch hot exhaust system components Hot components could cause a fire if exposed to combustible materials such as dry grass and weeds Always inspect the underside of the ATV after driving through tall grass weeds brush and other tall ground cover Promptly remove any grass or debris clinging to the vehicle Damaged components can cause loss of con trol resulting in serious injury or death After a rollover or an accident have a qualified ser vice dealer check the complete
17. doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level require ments Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system 112 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be main tained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or engine case near the clutch box NOTE The installation of devices that effectively
18. following the proce dure 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 control palety e Always check for obstacles before oper ating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth see page 106 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 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 Always use the size and type tires speci fied 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 Always remove the ignition key when the vehicle is not in use to prevent unautho rized use or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or P
19. hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation Install the wheel bolts and finger tighten them Lower the vehicle to the ground Securely tighten the bolts to 22 ft lbs 30 Nm 161 Maintenance Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized Polaris dealer Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer 162 Maintenance Tail Light Lamp Replacement If the brakelight doesn t work the lamp may need to be replaced 1 2 3 Remove the two screws securing the lens cover Remove the lens cover Remove the lamp and replace it with a new recommended lamp Test the light for proper operation Reinstall the lens cover 163 Maintenance Indicator Light Lamp Replacement Remove the handlebar cover or pod to access the lamps Remove the indicator wire connections from the harness Remove the nut from the back side of the indicator lamp Remove the lamp Apply dielectric grease to the socket and install the new lamp Reverse the steps to reinstall all components Oy ee tor 164 Maintenance Daytime Running Lights Lamp Replacement if equipped If the daytime running lights do not operate replace the lamps Polaris recommends that you install replacement lamps obtained
20. increase exhaust emissions beyond their legal lim its will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 113 Maintenance Periodic Maintenance Chart To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Record maintenance and service in the Maintenance Log beginning on page 198 114 Maintenance Periodic Maintenance Chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle Short trip cold weather operation 115 Maintenance Periodic Maintenance Chart A WARNIN
21. overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 95 Driving Safely Driving on Slippery Surfaces A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 96 Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 97 Driving Safely Driving Uphill A WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 98 Driving Uphill Whenever traveling uphill follow these precautions 1 Always travel straight uphill
22. part failure possible imbalance and exces sive engine RPM which can result in serious injury or death 41 42 Driver Warnings Be sure to read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your child s safety Be sure to explain to your young driver that the following hazards MUST be avoided at all times 43 Driver Warnings A 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 ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the oper ating techniques described in the Owner s Manual For more information about the ATV RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org 44 Driver Warnings A 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 abili
23. printed material and a video or DVD that instructs oper ators on safe operating procedures You should review this information with your child on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A A CAUTION The safety alert symbol on your vehicle or in this The safety alert caution indicates a potential haz manual alerts you to the potential for injury ard that may result in minor injury or damage to the vehicle A WARNING CAUTION The safety alert warning indicates a potential ys Alon oe hazard that may result in serious injury or death A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions Safety A WARNING Failure to follow the warnings in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or d
24. stop 9 Ignition Switch gt 9 Ignition Switch 10 Tether Switch D OUTLAW SPORTSMAN Never ride without the tether strap attached to your right wrist and to your ATV Be careful not A to let the cord get tangled around the handlebars or any part of your body 23 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off 24 Pre Ride Check We re almost ready to have an adult start your ATV But before the ATV is started for the first time you must do a Pre Ride Check In fact every time you want to ride you must have an adult help you check some things on your ATV before starting it Let s learn about these things now yw Make sure the throttle doesn t stick Check this by pushing the throttle 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 close to the handlebar the ATV has a sticky throttle This means that something is wrong or broken and must be fixed before you can ride your ATV safely Never start the engine if you have a sticky throttle You could be seriously hurt if you ride with A a sticky throttle Have an adult or your Polaris dealer fix the throttle before you ride 25 Pre Ride Check Make sure the brakes don t stick Check the brake levers by squeezing them toward the h
25. type 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 2 gallons 7 7 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel 180 Specifications Sportsman 90 Front Rack Capacity 15 Ibs 6 8 kg Rear Rack Capacity 30 Ibs 13 6 kg Front Rear Brakes Drum Parking Brake Mechanical Lock Front Tires 19 x7 8 3 psi Rear Tires 18 x 9 5 8 3 psi Dry Weight 289 Ibs 131 kg Length Width Height 61 75 157 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Brake Light Standard Daytime Running Lights Standard 181 Polaris Products Part Number Description Engine Lubricant 2876248 Synthetic Youth Oil qt 95 I 2876249 Synthetic Youth Oil gal 3 8 2872175 Semi Synthetic 20W 40 Oil qt 95 2872176 Semi Synthetic 20W 40 Oil gal 3 8 I 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 2872348 Chain Lube Aerosol 182 Polaris Products Part Number Descrip
26. with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner s manual for the ATV Always maintain proper tire pressure as stated in the specifications section of the owner s manual Driver Warnings A WARNING POTENTIAL HAZARD Operating the 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 or over turn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 106 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If neces sary apply them several times to let friction dry out the pads 63 Driver Warnings A WARNING A WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the ATV Operating the ATV with improper modifica WHAT CAN HAPPEN Overloading the ATV could cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this If equipped with racks cargo should be prop erly
27. 8 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 3 20 7 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 528 LBS 240 KG Reduce speed and allow greater distance for braking when carrying cargo Overloading or carry ing tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks With dual racks load distri bution 1 3 front 2 3 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 Safety Decals No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 39 Safety Decals Sportsman 90 Rack Warning WARNING DO NOT TOW WITH THIS VEHICLE Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 Ibs 6 8 kg Rear 30 Ibs 13 6 kg 40 Safety Decals Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause
28. Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer 187 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer 188 Engine Stops or Loses Power Troubleshooting Possible Cause Solution Out of fuel Turn the fuel valve to reserve refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery with 5 amp charger Incorrect fuel Replace with recommended fuel Clogged
29. G Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often under severe use such as in dirty or wet condi tions to purge water or dirt contamination from grease fittings and other critical components E Enmission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions E Dealer service item 116 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Miles Km Page E Steering Daily Check each day before operating 85 gt Front suspension i Ca es gt Rear suspension Daily list Tires Daily gt Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily gt Engine oil level Daily PE Air filter pre filter amp main Daily Inspect clean often replace as 156 element needed gt Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric 163 grease if replacing 165 117 Maintenance Periodic Maintenance Chart your dealer for adjustme
30. NG after stopping the engine A rolling vehicle can cause property damage and serious injury Always apply the parking brake 91 Driving Safely Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be dis played on the label 92 Long Helmet Sleeves 051039 0006 31 Driving Safely Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of strong ove
31. NTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE 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 191 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD 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 192 Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to 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 Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your d
32. Pantone 5777C Pantone 280CVC POLARIS The Way Out 2008 SPORTSMAN 90 OUTLAW 90 wner s Manual 0 for Maintenance and Safety AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVERUSE NEVERCARRY NEVER USE AN APPROVED ONPUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9921483 Rev 01 PRINTED IN TAIWAN Pantone 5777C Pantone 280CVC NEVER operate e 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 e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control gt POLARIS The Way Out AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance Visit us at www polarisindustries com POLARIS The Way Out POLARIS an
33. andlebar and then letting go They should come right back to where they were before you squeezed If they go back slowly or stay close to the handlebar your ATV has sticky brakes They must be fixed before you can ride your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride A with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you ride Have an adult check to see if your ATV needs more gas Children must never add their own gasoline This must always be done by an adult Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 78 of this manual 1 Always have an adult put gas in your ATV Never try to do it yourself 26 Pre Ride Check vw Ifyou used the storage area under the seat make sure the seat is locked in place yw Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running and it can burn your skin if you touch it Children must never check the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks yw This last check is done with the engine running You must check to make sure that all three ways to stop the engine of your ATV are working the way they should Do you remember what they are If you can t remember the three ways to stop the engine go back to page 24 and review Then have an adult h
34. ars can be adjusted for rider preference 1 Remove the pod to access the handlebar bolts Loosen the four bolts 2 Adjust the handlebar to the desired height Be sure the handlebars do not hit the gas tank or any other part of the vehicle when turned fully to the left or right 3 Lightly tighten each bolt equally to prevent uneven gaps in the block Torque the bolts to 7 3 ft lbs 10 Nm 158 Maintenance Tires A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less 159 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less HE 1 8 3 mm Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel bolts and remove the wheel 160 Maintenance Wheel Installation 1 2 3 Lock the parking brake Place the wheel in the correct position on the wheel
35. automotive oil See page 182 for the part numbers of Polaris products Under These Operating Conditions Use This Recommended Oil Outside air temperature is above 32 F 0 C Polaris Synthetic Youth Oil or Synthetic SAE40 Outside air temperature is below 32 F 0 C Semi Synthetic 20W 40 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 124 Maintenance Engine Oil Check Maintain the oil level within the safe range on the dipstick Do not overfill 1 Position the vehicle on a level surface 2 Remove the dipstick Wipe it dry with a clean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level NOTE Arising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe DP _ mark change the oil immediately 5 Add the recommended oil as needed 6 Reinstall the dipstick E Safe Range af Add Oil Full 125 Maintenance Engine Oil Change 1 Position the vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with s
36. 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 con dition Always follow the inspection and main tenance procedures and schedules described in the Owner s Manual 51 Driver Warnings A WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other stunts Avoid exhibition driving don t show off 52 Driver 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 make it harder 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 touch 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 opera tion 53 Driver 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 t
37. can be adjusted gradually depending on how much choke is needed for starting 5 Ifthe engine is cold use full choke by pushing the choke lever all the way to the left A warm engine will not require the use of the choke 6 Push the engine stop switch up to the ON position 7 Turn the ignition key to ON NOTE Do not press the throttle while starting the engine 89 Starting the Engine 8 Squeeze the rear brake lever and press the starter button NOTE The rear brake lever must be engaged or the engine won t start 9 Activate the starter for a maximum of five seconds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts 10 If the engine slows or stops position the choke lever half way to allow proper engine warm up Vary the RPM slightly with the throttle to aid in warm up 11 When the engine idles smoothly push the choke lever all the way to the right 90 Stopping the Engine 1 Release the throttle completely and brake to a complete stop 2 Shift the transmission to neutral 3 Stop the engine NOTE There are three ways to stop the engine e Turn the key off e Push the engine stop switch down e Pull the tether strap off the ATV NOTE To avoid draining the battery always turn the key to the OFF position when the engine is not running 4 Lock the parking brake A WARNI
38. corrosion to metal components If your vehicle is operated in salt water areas rinse it off frequently with fresh water 137 Maintenance Spark Arrestor To remove accumulated carbon clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 114 A WARNING Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool suf ficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas 138 Maintenance Spark Arrestor 1 Remove the six bolts and remove the arres tor from the end of the muffler 2 Use anon synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage Replace the arrestor if damage is found 4 Reinstall the arrestor 5 Torque the bolts to 7 ft Ibs 9 5 Nm Arrestor Screer 139 Maintenance Carburetor IMPORTANT Your Polaris ATV is calibrated at the factory for optimal performance at alti tudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximat
39. cured by cot ter pins Fuel and oil Check and fill as needed 78 80 Throttle Check for proper operation 25 70 71 Engine stop switch Check for proper function 68 Daytime running lights if equipped Check for proper operation 165 Brakelight Check for proper operation 163 86 Pre Ride Inspection Pre Ride Checklist Item Remarks Page Air filter pre filter Inspect clean or replace 156 Drive chain Check condition and slack refer to drive 153 chain adjustment Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any damaged com ponents or loose fasteners Riding gear Wear helmet goggles protective cloth 92 ing 87 Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness result ing in severe injury or death Never run an engine in an enclosed area CAUTION Operating the ATV immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating 88 Starting the Engine Shift the transmission to neutral Lock the parking brake Turn the fuel valve on AWN Sit on the vehicle and attach the tether strap to the ATV and to your right wrist NOTE The choke is fully on when the lever is pushed completely to the left The choke is off when the lever is pushed completely to the right The choke
40. d POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc Copyright 2007 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is expressly prohibited Printed in USA 2008 Outlaw 90 Sportsman 90 ATV Owner s Manual P N 9921483 2 Welcome Dear Parents We believe your children should have the opportunity to enjoy The Way Out experience along with you We ve provided this owner s manual to assist you and your children in learn ing about safe operation and care of your new ATV Please review the information in this manual with any child who may operate the ATV Help your children learn to operate the ATV with safety as a top priority Help them also learn to show respect for our environment and for the rights of others while operating the ATV Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Always supervise your child s use of the ATV and p
41. e Capacity 131 GlOVeS besiege 93 H Handlebar Adjustment 158 Hauling Cargo 110 111 Helmet se 085 0 ee a EOE 92 HOP oes bie eS ik Se aes 69 Horn Button 0 19 Indicator Light Indicator Lights Kick Start Lever rae e anne Lamp Replacement Daytime Running Lights Indicator Light Lights Indicator Lights Daytime Running Lubrication Guide Main Key Switch Maintenance Chart N No Passenger Warning 39 O Oil ccs Sees e hehe tee ease 124 Oil Change Engine 126 128 Oil Change Transmission 131 Oil Check Engine 125 Oil Check Transmission 130 Oily Engine oreo swe an r wlll ae 124 Operation Warning 35 P Parking on a Hill or Incline 105 Passenger Warning 39 Periodic Maintenance Chart 114 121 Polaris Products 182 Polishing reete 172 Pre Ride Inspection 85 87 Product Safety Commission 14 R Rack Warning 40 Riding Gear 92 93 S Safety Training T Seat Lateh oeri 4e c2nieadesacnes 21 Sevete Use De r ar GE EN 115 Shift Lever 25 5 scscd aa oat 20 72 Shock Spring Adjustment 152 Signal words 0 8 Spark Arrestor 138 139 Spark Plug Change 133 Spark Plugs 132 133 Specifications Outlaw 90 178 179 Sportsman 90 180 181 Speed Control System
42. ealer require any additional assistance they will contact the appropriate personnel 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 Recommended Lubricants 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 193 Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s war ranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move o
43. elp you start the engine Practice stop ping the engine all three ways 27 Riding Rules Now you re ready to learn about riding your Polaris ATV There are some things you can do and there are some things you must never do Rules are very important when you re driving an ATV Adults have riding rules too The rules help keep us safe when we ride gt The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always drive safely Let s learn how to ride Always follow the safe riding rules found on the next pages You or others around you could A be seriously hurt if you don t follow the safe riding rules 28 gt Always wear the right kind of clothing and safety gear when riding your ATV Helmet Your helmet is very important for safe riding A helmet can prevent a severe head injury Eye Protection Always wear shatterproof goggles or a helmet face shield and always keep them clean so you can see where you re driving Gloves Wear gloves to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from scrapes and scratches Clothing Make sure your clothing fits properly If it s too small it could keep you from moving easily when Riding Rules Long Sleeves you shift your weight If it s too big it could hang down and get ca
44. ely 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor per formance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 140 Maintenance Carburetor If the engine idle speed is not satisfactory and all other conditions are favorable the carbure tor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclock wise will lower RPM 141 Maintenance Speed Control System Per ANSI SVIA 1 2001 sec 6 1 3 AS DELIVERED TO THE CONSUMER the speed of youth models is restricted to under 10 MPH for the 50cc models and under 15 MPH for the 90cc models The dealer CANNOT under any circumstances either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable th
45. ermit continued use only if you determine that your child has the ability and maturity to operate the ATV safely Never allow a child to operate the ATV without adult supervision The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child s ATV are thoroughly inspected at various intervals For safe and enjoyable operation of the vehicle be sure to follow all of the instructions and rec ommendations in this manual If you have any questions about the ATV contact a Polaris dealer for assistance Welcome Dear Children Before you ride your new Polaris ATV there are some important things that you need to know Your parents and Polaris want you to enjoy riding your new ATV and that s why you need to read and understand the information in your owner s manual Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re riding So read your manual and then enjoy riding your new Polaris ATV Safty oeii etal haw eee hea Youth Section Know Your ATV Pre Ride Check Riding Rules Table of Contents Adult Section 33 Safety Decals 34 Driver Warnings 43 Vehic
46. ers 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 DEALER FOR A REPLACEMENT 35 Safety Decals Age Warning WARNING 36 Kids under age 12 should NEVER operate this ATV Kids under 12 have an increased chance of losing con trol 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 or DVD and complete the ATV RiderCourse Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns Safety Decals Outlaw 90 Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 3 20 7 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 453 LBS 206 KG 37 Safety Decals Sportsman 90 Tire Pressure Warning 3
47. esult in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation 70 Features and Controls Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement Engine speed returns to idle when the lever is released This ATV is equipped with an Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will Throttle stop and power to the rear wheels will cease Lever 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 attempt to modify the ETC system or replace it with any after market throttle mechanism 71 Features and Controls Shift Lever To change gears stop the ATV With the engine idling move the lever to the desired gear Do not try to shift gears with engine speed above idle or while the ATV is mov ing Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Shift Pattern F Forward Gear N Neutral R Reverse 72 Features and Controls CAUTION Do not attempt to sh
48. et road or highway In many states it is illegal to operate ATVs on public streets roads and highways 48 Driver Warnings A WARNING POTENTIAL HAZARD Operating this ATV without wearing protective gear WHAT CAN HAPPEN Operating without an approved helmet increases the risk of a severe head injury or death in the event of an acci dent Operating without eye protection and protective clothing can also result in injury HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 49 Driver Warnings A WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs WHAT CAN HAPPEN Your judgment could be seriously affected You may react more slowly Your balance and perception will be affected You could have an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV 50 Driver Warnings A WARNING A 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 accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience POTENTIAL HAZARD Failure to inspect the ATV
49. from your authorized Polaris dealer 1 2 3 4 Dn Remove the front cab Outlaw only Disconnect the lights from the harness Remove the rubber cover from the back of the light assembly Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out Install the new lamp Make sure the filament is horizontal Reinstall the lamp retainer Press the retainer inward and turn it clockwise about 1 4 turn Start the engine to make sure the lights come on If the lights do not operate see your Polaris dealer for service Reinstall the rubber cover and reconnect the lights to the harness Reinstall the front cab Outlaw only 165 Maintenance Battery The battery in your Polaris ATV is a sealed battery The sealing strip cannot be removed Never add water to this type of battery Keep the battery terminals and connections 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 shop towels Coat the terminals with dielectric grease or petroleum jelly A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery
50. he ATV Maintain the oil level at the bottom of the fill plug hole threads Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 182 for the part numbers of Polaris prod ucts 1 Position the vehicle on a level surface Remove the fill plug View the oil level through the fill hole If the level is low add the recommended oil Reinstall the fill plug Drain Plug Vi ce aa oe 130 Maintenance Transmission Oil Change Position the vehicle on a level surface Remove the fill plug Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm Add the recommended oil Maintain the oil level at the bottom of the fill plug hole threads Reinstall the fill plug Check for leaks Dispose of used oil properly ONY gRr ONS Cet Gearcase Capacity Outlaw 90 11 8 oz 350 ml Sportsman 90 11 8 oz 350 ml 131 Maintenance Spark Plugs Refer to the specifications section beginning on page 178 for spark plug and gap specifica tions CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris rec ommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition sh
51. hicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the vehicle is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Turn the fuel valve off 3 Check the air box for any water and dry it if water is present 4 Remove the spark plug 134 Maintenance Vehicle Immersion 5 Loosen the carburetor drain screw 6 Turn the engine over several times using the electric start 7 Piy the spark plug and reinstall it or replace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the transmission follow the pro Drain Screw cedure on page 137 for drying the CVT 135 Maintenance Constant Variable Transmission CVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the CVT system Doing so may reduce its strength so that a failure may occur at a high speed The CVT system has been precision balanced Any m
52. hill when possible 58 Driver Warnings A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 102 Use extra caution when turning on any hill Avoid crossing the side of a steep hill 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 surfaces Shift your weight to the uphill side of the ATV 59 Driver Warnings A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climb ing a hill WHAT CAN HAPPEN The ATV could overturn and cause injury HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If you lose all forward speed Keep your weight uphill Apply the front brakes gradually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake 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 When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side
53. ift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle Always place the transmission in gear with the parking brake applied and turn the vehicle off when ever the vehicle is left unattended 73 Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes Rear Brakes Front Brakes A WARNING Applying only one brake could cause loss of control and result in serious injury or death Always apply both brakes at the same time 74 Features and Controls Brakes Parking Brake 1 2 Squeeze the left brake lever Not Locked Push the parking brake lock down to lock the brake lever in place To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically A WARNING Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operating the ATV 75 Features and Controls Brakes Parking Brake 1 Always shift the transmission to neutral and lock the parking brake before starting the engine 2 After the engine has warmed enough fo
54. ills and follow proper operating procedures outlined in the owner s manual Ifthe vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while maintaining body weight uphill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 102 Driving Safely Turning Around on a Hill 5 6 Shift the transmission to forward gear Release the parking brake and drive slowly Staying uphill of the ATV turn the handle bars full left While holding the brake release the park ing brake lock and slowly release the brake allowing the ATV to roll around to your right until it s pointing across the hill or slightly downward Lock the parking brake and remount the ATV from the uphill side maintaining body weight uphill Restart the engine Squeeze the rear brake lever controlling speed with the rear brake until the ATV is on more level ground 103 Driving Safely Driving Downhill Whenever descending a hill follow these precautions 1 Drive directly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the front and rear brakes at the same time and very slightly to aid in slowing A WARNING
55. ime to react This could cause the ATV to overturn or go out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV 54 Driver Warnings A WARNING POTENTIAL HAZARD Failure to use extra caution when operating on exces sively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills nec essary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 55 Driver Warnings A WARNING A WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 56 POTENTIAL HAZARD Towing or pulling an object behind the ATV WHAT CAN HAPPEN A wagon sled or other object towed behind an ATV does not have brakes or steering The object may over
56. in the proper range See page 125 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 85 6 Perform the following maintenance at the end of the break in period Item Remarks See Page Engine oil change Perform break in oil change 126 Oil pre filter screen Clean filter with oil change 127 Transmission oil Perform break in oil change 130 Valve clearance See your dealer for inspection and adjustment 84 Pre Ride Inspection A WARNING If a proper inspection is not done before each use severe injury or death could result Always inspect the ATV before each use to ensure it s in proper operating condition Pre Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 145 149 Front suspension Inspect lubricate if necessary 122 Rear suspension Inspect lubricate if necessary 122 Steering Ensure free operation lubricate if neces 150 152 sary 85 Pre Ride Inspection Pre Ride Checklist Item Remarks Page Tires Check condition and pressure 159 Wheels fasteners Inspect ensure fastener tightness 161 162 check that axle nuts are se
57. ing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle 169 Maintenance Cleaning Washing the ATV The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 170 Maintenance Cleaning Washing the ATV If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the following items e Wheel bearings e Brakes e Radiator e Cab and body panels Transmission seals e Labels and decals NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine t
58. is provided in the tool kit for removing or installing the lever If not installed make sure the rubber cap is on the kick start shaft to protect the rider Store the lever under the seat when it s not installed 5 Push the engine stop switch up to the ON position 6 Turn the key to ON 7 Place your foot on the kick start then thrust your heel downward to crank the engine 8 After the engine has started fold the kick start lever back into place Kick Start Lever 82 Break in Period The break in period for your new Polaris 4 cycle ATV is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Per form the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 83 Break in Period 1 Fill the fuel tank with gasoline See page 78 2 Check the oil level Add the recommended oil as needed to maintain the oil level
59. ity of the owner including the parts labor and other costs associated with recommended maintenance 196 Warranty U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIM ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS 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 if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing com petition
60. kin 126 Maintenance Engine Oil Change 5 Place a drain pan under the engine crankcase 6 Remove the pre filter plug Allow the oil to drain completely 7 Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry 8 Clean the pre filter plug Install a new sealing washer on the plug NOTE The sealing surfaces on the plug and crankcase should be clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug 127 Maintenance Engine Oil Change 10 Reinstall the pre filter drain plug Torque to 11 ft Ibs 15 Nm 11 Remove the dipstick Add 29 oz 850 ml of the recommended oil Do not overfill NOTE See the specifications section beginning on page 178 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the engine and inspect for leaks 15 ce the oil level Add oil as needed to bring the level to the upper mark on the dip stick 16 Dispose of used oil properly 128 Maintenance Fuel Filter The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 114 Do not attempt to clean the fuel filter 129 Maintenance Transmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of t
61. le Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 185 Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer 186 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with 5 amp charger Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace
62. le ID Numbers 66 Features and Controls 67 Break in Period 83 Pre Ride Inspections 85 Starting the Engine 88 Stopping the Engine 91 Driving Safely 92 Emission Control 112 Maintenance 114 Specifications 178 Polaris Products 182 Troubleshooting 184 Warranty 5h etree a8 at 190 Maintenance Log 198 INDOX oes a wes 202 Safety Understand the Warnings Always follow the age guidelines for your ATV Never allow a younger child to ride on or drive the ATV Make sure all operators have completed an approved ATV safety training course such as the SVIA RiderCourse and understand all warnings and the owner s manual before driving the ATV Know Your ATV Before Riding Parents must help their children learn the proper and safe way to ride an ATV Read the owner s manual with your children before starting the engine for the first time and review it with them periodically afterwards Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligi ble family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCourse In addition you were provided with
63. low it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stop the engine Turn the fuel valve off 6 Drain the carburetor bowl 174 Maintenance Storage Engine Oil Change the oil See page 126 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 114 e Transmission Oil Engine Oil e Brake Fluid 175 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 114 Storage Area Covers 1 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated 4 Cover the vehicle with an appropriate cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent con densation and may promote corrosion and oxidation 176 Maintenance Transporting the ATV Follow these procedures when transporting the ATV Stop the engine Place the transmission in gear Lock the parking brake Secure the fuel cap oil cap and seat Turn the fuel valve off ON Be Ge O a Always tie the frame of the ATV t
64. means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Start Button Choke Lever Use the choke to start a cold engine Push the choke lever to the left before starting the engine When the engine starts gradually return the choke lever to the OFF position as the engine warms up and runs smoothly Choke Lever 68 Features and Controls Horn Button Use the horn for emergencies and to let others know you re near Engine Start Button The start button is located slightly above the choke lever 1 2 Dy Be Attach the tether strap securely to the vehicle and to the rider s right wrist Shift the transmission to neutral The neutral light will come on when the lever is in neu tral See page 77 Turn the key to the ON position Lock the parking brake Push the engine stop switch up to the ON position Press the start button 69 Features and Controls Throttle Controls A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can r
65. n ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this 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 jumps or other stunts Never tow or pull an object behind the ATV Safety 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 handle bars 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 con ditions when operating the ATV Never operate on excessively rough slip pery or loose terrain Safety 12 Always follow proper procedures for turning as described in this manual Prac tice turning at low speeds before attempt ing to turn at faster speeds Do not turn at excessive speed Always have the ATV checked by an authorized Polaris 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 e Alway
66. nd rear gearcases if equipped and all grease fittings CAUTION Major engine damage can result from driving this ATV in deeper water than recommended If your vehicle becomes immersed or is operated in water that exceeds the bottom of the footrests take it to your dealer for service before starting the engine 107 Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the ter rain you re traveling on Be constantly alert for hazards such as logs rocks and low hang ing branches A WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 108 Driving Safely Driving in Reverse Follow these guidelines when operating in reverse Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Always avoid backing downhill Never open the throttle suddenly while backing Always look left right and behind the ATV before backing A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse opera tion procedures outlined in this manual Always back slowly ON Oo 109 Driving Safely Hauling Cargo The Sportsman 90 was designed with racks to carry small loads
67. nts Item Maintenance Interval Remarks whichever comes first a Hours Calendar Miles Km age Drive chain Daily Inspect daily adjust and lubricate 153 if needed CVT housing if equipped Weekly Drain water as needed check 137 often if operating in wet conditions Break in Maintenance After first 10 hours of operation Perform break in maintenance 83 gt E Brake lever travel brake 10 Monthly 100 160 Inspect regularly 145 freeplay 149 HE Spark plug 10 Monthly 100 160 Clean check condition adjust 132 gap replace as needed Idle speed 10 Monthly 100 160 Check adjust as needed 141 ME Choke 10 Monthly 100 160 Check for proper operation see gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service E Have an authorized Polaris dealer perform these services 118 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first Soe Hours Calendar Miles Km age Battery 20 Monthly 200 320 Check terminals clean test 166 gt Engine oil change 30 6M 300 480 Drain and change the oil 126 gt Transmission oil 40 12M 400 640 Drain and change the oil 130 gt Oil pre filter screen 40 12M 400 640 Clean filter at every oil change 127 clean annually if ATV is operated less than 10 hours gt General lubrication 50 3M 500 800 Lubricate all fittings pivots
68. o run for a while to evaporate any water that may have entered the engine or exhaust system 171 Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips TON the use of automotive products some of which can scratch the finish of your vehi cle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 172 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended See page 169 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge 173 Maintenance Storage Stabilize the Fuel Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount NOTE Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Start the engine and al
69. o the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting the unit Accessories Polaris has a wide range of accessories available for your ATV Please see your Polaris dealer 177 Specifications Outlaw 90 Rider Capacity Maximum Weight 1 Rider 170 lbs 77 kg Displacement 89cc Cooling Air Cooled Engine type 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gallons 6 4 liters Fuel Reserve Capacity 23 gallons 86 liters Starting Electric with kick start backup Drive System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel 178 Specifications Outlaw 90 Front Rear Brakes Drum Parking Brake Mechanical Lock Front Tires 19x 7 8 3 psi Rear Tires 18 x 9 5 8 3 psi Dry Weight 270 Ibs 122 4 kg Length Width Height 61 25 156 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Brake Light Standard Daytime Running Lights Standard 179 Specifications Sportsman 90 Rider Capacity Maximum Weight 1 Rider 170 lbs 77 kg Displacement 89cc Cooling Air Cooled Engine
70. odification will cause the system to be out of balance creating vibration and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product How ever as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This CVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the CVT housing is securely in place during operation 136 Maintenance CVT Drying There may be some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operating The drain plug is located on the bot tom of the CVT cover 1 2 3 ci Remove the drain plug Allow the water to drain Reinstall the drain plug Shift the transmission to neutral Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible CAUTION Exposure to salt water will cause
71. often under severe use such as in dirty or wet conditions See page 182 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t use a high pressure washer or gasoline to clean the drive chain CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifica tions 153 Maintenance Drive Chain Slack 1 Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain 2 Collapse the suspension with an adjustable buckle type trailer tie down strap Fasten the strap around the axle and rear bumper tube 3 Tighten the strap until a straight line can be drawn from the rear axle to the gearcase output shaft intersecting the swing arm pivot This establishes the tightest chain position 4 Pull down on the chain tensioner to move it out of the way then measure chain slack It should have 1 4 1 2 6 12 mm deflection 5 Ifthe chain needs adjustment Tensioner use the procedure on page 155 154 Maintenance Drive Chain Slack Adjustment CAUTION Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud 1 Loosen the four rear housing mount b
72. olaris at 1 800 342 3764 14 Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories may change the handling characteristics of the ATV Use only Polaris approved accessories and familiarize yourself with their function and effect on the ATV 15 16 Know Your ATV PARENTS Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider s skill and experience More information on speed limiting functions can be found beginning on page 142 These units are not designed for adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded See the specifications section beginning on page 178 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know You
73. olts 2 Loosen the chain adjuster lock nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft Ibs 4 25 Nm 5 Tighten the four rear housing mount bolts to 43 ft Ibs 60 Nm inny Housing Mount Chain Adjuster Bolts 155 Maintenance Air Filter 1 Remove the seat See page 21 2 Release the air box cover spring clips and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply acommercially available foam filter lubricant to the foam filter Cover Foam Filter Support Screen 156 Air Filter 5 Clean away any oil or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat Maintenance CAUTION Never operate the ATV with the filter element removed Dirt will enter the engine causing rapid wear and severe damage to the engine 157 Maintenance Handlebar Adjustment A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service The handleb
74. ould be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color A WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 132 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Change 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclock wise to remove it 3 Reverse the procedure for spark plug installation Torque to 14 ft Ibs 19 Nm 133 Maintenance Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service or after 25 hours Ve
75. page 81 78 Features and Controls Fuel System A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 79 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars Use unleaded gasoline with a minimum pump octane of 87 Refer to the specifications sec tion beginning on page 178 for fuel tank capacity 80 Fuel Valve The fuel valve is located on the left side of the ATV It has three settings OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling Features and Controls Sportsman 90 Fuel Valve ise Fuel Valve OFF ON RES 81 Features and Controls Kick Start Lever If the battery becomes too weak to start the engine use the kick start lever to start the engine until the battery is serviced 1 Position the vehicle on a level surface 2 Shift the transmission to neutral 3 Lock the parking brake 4 Fold out the kick start lever on the left side of the ATV NOTE A 10 12mm wrench
76. r are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the sell ing dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair 194 Warranty EXPORTED VEHICLES How to Get Service If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and
77. r operation shift to the desired gear 3 Release the parking brake and gently apply the throttle 4 Always lock the parking brake whenever the vehicle is left unattended 76 Features and Controls Lights A WARNING Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark Do not operate this ATV after dark Use caution and drive at reduced speeds in conditions of reduced visi bility This ATV is designed for off road use only Do not operate this ATV on streets or highways Indicator Lights Indicator lights on the ATV let you know when your ATV is in neutral or reverse Reverse OUTLAW SPORTSMAN 77 Features and Controls Fuel System A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is per formed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the ATV is stored or parked See
78. r safety and the safety of others is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re riding Pay attention when you see this symbol This is the safety alert symbol When you see this symbol on your ATV or in this manual it A means PAY ATTENTION because you could die or be seriously injured if you don t follow the instructions 18 Know Your ATV Before you have an adult start the engine for you for the first time let s learn about the con trols on your new ATV 1 2 3 Engine Stop Switch When the engine is running push this button down to shut the engine off quickly The button must be up before you can start the engine again Horn Button Press the horn button to sound the horn Throttle Control Press the throttle lever with your thumb when you want the ATV to go forward Always make sure the throttle control does not stick before you drive your ATV Read more about it on page 25 2 Horn Button Toename Stop Switch 3 Throttle Control Know Your ATV 4 Kick Start Lever If your battery is 20 too weak to start your ATV you can push down on the kick start lever with your foot to start the engine Have an adult show you how it works Read more about how to use the kick start on page 82 Shift Lever The shift lever is on the right side of your ATV Read about how to use the shift lever on page 72
79. r the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with knee pads and a jersey with shoulder pads provide the best protection 93 Driving Safely Driving Procedure 1 Sit upright with both feet on the footrests and both hands on the handlebars 2 Shift the transmission to neutral 3 Start the engine and allow it to warm up Check your surroundings and determine your path of travel Squeeze the left brake lever gt Shift the transmission to the desired gear Slowly release the brake lever ONY Slowly press the throttle with your right thumb and begin driving 9 Drive slowly at first Practice turning and using the throttle and brakes on level surfaces 94 Driving Safely Making Turns Your ATV is 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 footrest This technique ceils alters the balance of traction between the rear _ wheels allowing the turn to be made smoothly NOTE Practice making turns at slow speeds A WARNING Turning at sharp angles or at excessive speeds can result in vehicle
80. riving on hills or over obstacles if you fail to take proper precau tions Read and understand the owner s manual and all warnings before operating a Polaris ATV Safety 10 Read this manual and all labels carefully Follow all operating procedures Never operate an ATV without proper instruction Take a training course Pur chasers of a new Polaris ATV and age eli gible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse Always follow the age guidelines for your vehicle Y 12 90cc models are designed for children not less than 12 years of age and Y 6 50cc models are designed for children not less than 6 years of age No child under the age of 16 should ride any 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 or DVD and taken and completed an approved ATV safety training course such as the ATV RiderCourse Always avoid operating an ATV on any paved surfaces including sidewalks driveways parking lots and streets Never operate an ATV on any public street road or highway including dirt or gravel roads Always be sure there are no obstacles or people behind your ATV when operating in reverse Drive slowly and avoid turn ing at sharp angles in reverse Never operate a
81. rottle limiting screw Speed limiting devices may be adjusted removed only by consumers when they determine that their child is capable of han dling the additional speed Per ANSI SVIA 1 2001 sec 6 2 the unrestricted top speed is less than 15 MPH for the 50cc models and less than 30 MPH for the 90cc models 142 Speed Control System Throttle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten the jam nut after adjusting Maintenance 143 Maintenance Throttle Cable Adjustment Always check the throttle for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay falls in to the acceptable limit 144 Nut 1 16 1 8 1 5 3 2 mm Maintenance Brake Freeplay Measure Freeplay Check measure the freeplay of the front and rear brakes at the intervals rec ommended in the Periodic Maintenance Chart beginning on page 114 If the freeplay isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specifications Model Front Brake Rear Brake 90cc Models 08 12 2 3 mm 08 12 2 3 mm 145 Maintenance Brake Freeplay Front Brake Adj
82. s 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 excessively 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 e Always follow proper procedures for going down hills and for braking on hills as described 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 e 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 turn ing technique described in this manual on level ground Avoid crossing the side of a steep hill Safety e Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards 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
83. ties or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD Follow the age recommendations for this ATV 45 Driver Warnings A WARNING POTENTIAL HAZARD Carrying a passenger on this ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces your ability to balance and control this ATV Carrying a passenger could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for passengers 46 Driver Warnings A WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces including sidewalks paths parking lots and driveways 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 possible If you must ride on a paved surface go slowly and do not make sudden turns or stops 47 Driver 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 paved or unpaved public stre
84. tion Grease 2871322 All Season Premium Grease 3 0z 89 ml 2871423 All Season Premium Grease 14 0z 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus 183 Troubleshooting See your Polaris dealer if you re unable to identify solutions using the following charts Engine Turns Over Fails to Start Possible Cause Solution Out of fuel Turn the fuel valve to reserve refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery voltage Recharge battery with 5 amp charger Mechanical failure See your Polaris dealer 184 Engine Doesn t Turn Over Troubleshooting Possible Cause Solution Low battery voltage Recharge battery with 5 amp charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possib
85. turn or collide with other objects and cause serious injuries HOW TO AVOID THE HAZARD Never tow or pull an object behind the ATV Driver Warnings A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner s Manual beginning on page 98 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward 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 vehicle or person could be on the other side of the hill 57 Driver Warnings A WARNING POTENTIAL HAZARD Going down a hill improperly WHAT CAN HAPPEN Driving downhill improperly could cause loss of control or ATV overturn HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner s Manual See page 104 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
86. ught in a moving part Wear long sleeves and long pants to protect your arms and legs 29 a Rules gt Always attach the tether strap to your right wrist and to the ATV before riding Make sure you know where you re going to drive before your ATV is started Make sure the area is safe all around your ATV 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 Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests Always be alert and pay attention to where you re driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do Never follow another ATV too closely You need lots of time and space to stop your ATV gt Never tow or pull an object behind the ATV 30 v Vv V Vv VV vv Y Riding Rules Never ride alone An adult should always be watching you in case you need help Always drive within the sight of an adult Never ride on public trails 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 Don t ride at night Your ATV doesn t have lights that are safe for driving in the dark Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them
87. ustment 1 2 3 146 Position the vehicle on a level surface Shift the transmission to neutral Elevate the front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground Front B ke While rotating the eft front wheel Adjuster Nuts tighten the upper front brake adjuster nut on the right hand control When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn Maintenance Brake Freeplay Front Brake Adjustment 6 While rotating the right front wheel tighten the ower front brake adjuster nut on the right hand control 7 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 8 Verify that the right hand brake functions correctly Verify that brake lever freeplay is at specification See page 145 10 Carefully lower the vehicle to the ground 147 Maintenance Brake Freeplay Rear Brake Adjustment 1 Position the vehicle on a level surface 2 Shift the transmission to neutral 3 Elevate the rear of the vehicle by placing a suitable stand under the frame The rear tires should be slightly off the ground 4 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 5 When you begin to feel a slight drag in wheel rota tion loosen the wing nut one full turn 6 Verify that the left hand brake functions correctly 7 Verify that brake le
88. vehicle includ ing but not limited to brakes throttle and steering for possible damage A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 65 Vehicle Identification Numbers Record your ATV s identification num bers and key number in the spaces pro vided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number Frame VIN Engine Serial Number Key Number on the key 66 Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running Key A Q a D OUTLAW SPORTSMAN A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 67 Features and Controls Engine Stop Switch Horn Stop Switch The engine will not start or run when the stop switch is down in the OFF position Its pur pose is to provide the operator with a quick
89. ver freeplay is at specification See page 145 8 Carefully lower the vehicle to the ground TT dle Rear Brake Wing Nut 148 Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 114 When freeplay specifications can no longer be obtained through adjustment as outlined on the preceding pages use the following information to determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table below Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting Measure Lever Travel Component Total Lever Travel Front brake lever 1 3 4 45 mm Rear brake lever 2 1 2 65 mm 149 Maintenance Toe Alignment A WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 1 Set the handlebars in a straight ahead position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post
90. you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 195 Warranty U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibil

Polaris 9921483 Offroad Vehicle User Manual

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