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Polaris 419C Offroad Vehicle User Manual

1. Oil Full 109 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 Stopthe engine CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 110 Maintenance Engine Oil Change 5 6 ds Place a drain pan under the engine crankcase Remove the pre filter plug Allow the oil to drain completely Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry Clean the pre filter plug Install a new sealing washer on the plug The sealing surfaces on the plug and crankcase should be clean and free of burrs nicks or scratches Reassemble the pre filter screen and spring to the pre filter plug 111 Maintenance Engine Oil Change 10 Reinstall the pre filter drain plug Torque to 11 ft 165 15 Nm 11 Remove the dipstick Add 29 oz 850 ml of the recommended oil Do not overfill See the specifications section beginning on page 162 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 Check 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 112 Maintenance Fuel Filter The POLARIS is equipped with an in line fuel
2. 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 Front Rack Capacity 15 Ibs 7 kg Rear Rack Capacity 30 Ibs 14 kg Front Rear Brakes Drum Parking Brake Mechanical Lock 165 Specifications SPORTSMAN 90 Front Tires 19 x 7 8 3 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa 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 Carburetor Settings Cutaway n a Pilot Air Screw 1 25 turns out Needle Jet 11 Pilot Jet 40 Main Jet 80 E Clip Position 314 from top 166 SPORTSMAN 90 Carburetor Jetting Specifications Shaded cells indicate factory settings AMBIENT TEMPERATURE Meters Feet Below 25 30 to 10 15 to 5 Oto 20 15 35 30 to 50 45 to 65 Above 60 C Below 35 34t0 23 26to 15 18to 7 9to 2 1to 10 7to 18 Above 16 Main Je 82 82 82 82 80 80 80 80 2000 Pilot Je 42 42 40 40 40 40 40 40 Clip Position
3. Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 11 12 13 Operation Never operate a damaged ATV After any overturn or accident have a quali fied service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust system com ponents Always keep combustible materials away from the exhaust sys tem Always remove the ignition key when the vehicle is not in use to prevent unau thorized use 75 Operation Starting the Engine NOTICE Operating the ATV immediately after starting could cause engine damage Allow the engine Pon Tip 6 76 to warm up for several minutes before operating Shift the transmission to neutral Lock the parking brake Turn the fuel valve on Sit on the vehicle Attach the tether strap to the ATV and to your wrist 5 If the engine is cold use full choke by Full Choke 4 pushing the choke lever all the way to the left A warm engine will not require the use of the choke 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 can be adjusted gradually depending on how much choke is needed for starting Push the engine stop switch up to the ON position Operation Starting the Engine 7 Turn the ignition key to ON 8 Squeez
4. 8 9 Safety Warnings 13 30 Age Restrictions 13 Carrying a Passenger 17 Crossing Hillsides 23 Descending Hills Improperly 22 Excessive Speeds 19 Exposure to Exhaust 15 Failure to Inspect 16 Frozen Bodies of Water 30 Handling Gasoline 15 Hot Exhaust Systems 30 Improper Cargo Loading 29 Improper Hill Climbing 21 S S T Safety Warnings 13 30 Shock Spring Adjustment 136 Tail 147 Improper Tire Maintenance 26 Sidehilling cete 86 Tether 45 Improper Modifications 27 Signal words 6 Throttle decederet 60 Jumps and Stunts 20 Spark Arrester 122 123 Throttle Cable Adjustment 128 Operating a Damaged ATV 30 Spark Plug Change 117 Throttle Control 41 Operating on Pavement 18 Spark Plugs 116 117 Throttle Lever ns sags en 61 Operating on Public Roads 18 Specifications Throttle Stop Speed Control 127 Operating on Steep Hills 21 OUTLAW 90 esu 162 164 Tire Tread Depth 144 Operating Over Obstacles 27 SPORTSMAN 90 165 167 143 Operating in Deep Water 28 Speed Control System 126 127 Toe Alignment 134 135 Operating Without Instruction 14 Start Button 59 Transmission Oil 114 115 Physical Co
5. 2 Place the handlebars in a straight ahead position 3 Tiealength of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 134 Maintenance Toe Alignment 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measure ment on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment Repeat the measurement procedure on the other side of the vehicle If you discover improper alignment see your POLARIS dealer for service 135 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 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 136 Maintenance Drive Chain Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 98 Lubricat
6. Engine oil level Daily Fuel Tank Daily Ada Carbon Clean with each fuel 66 Ill Air filter pre filter amp main Daily Inspect clean often replace as 140 element needed Air box sediment tube Daily Drain deposits when visible Daytime running lights tail Daily Check operation apply dielectric 147 lamp grease if replacing 149 101 Maintenance Periodic Maintenance Chart Remarks E Emission Related Service D Have an authorized POLARIS dealer perform these services 102 Item Maintenance Interval whichever comes first PR Hours Calendar Miles Km 88 Drive chain Daily Inspect daily adjust and lubricate 137 if needed CVT housing if equipped Weekly Drain water as needed check 121 often if operating in wet conditions Break in Maintenance After first 10 hours of operation Perform break in maintenance 69 gt Brake lever travel brake 10 Monthly 100 160 Inspect regularly 129 D freeplay 133 E Spark plug 10 Monthly 100 160 Clean check condition adjust 116 gap replace as needed Idle speed 10 Monthly 100 160 Check adjust as needed 125 D Choke 10 Monthly 100 160 Check for proper operation see E your dealer for adjustments gt Perform these procedures more often for vehicles subjected to severe use Periodic Maintenance Chart Maintenance Item Maintenance Interval Remar
7. Indicator Light 148 Indicator Lights 65 Instruction Operating 14 K Key diede doe otc 57 Kick Start Lever 42 68 K THE ee eee teet eese 88 L Lamp Replacement Daytime Running Lights 149 Indicator Light 148 Tail Light 147 Lights uec enr 65 Lights Daytime Running 149 Lights Indicator 65 Lubrication Guide 106 107 196 M Main Key Switch 57 Maintenance Chart 98 105 Making Turns 80 Modifications 12 o TED 108 Oil Change Engine 110 112 Oil Change Transmission 115 Oil Check Engine 109 Oil Check Transmission 114 Oil Engine i ces ee rr ees 108 Operator Restrictions 13 P Parking on a Hill or Incline 90 Periodic Maintenance Chart 98 105 Polaris Products 168 169 iocus merge eam 156 Pre Ride Inspection 72 13 R Restrictions Age 13 Riding Gear 4c coce a ca ays 10 11 S Safe Operation Practices 74 15 Safety Labels Age Warning 32 Clutch Cover Warning 38 Discretionary Warning 34 No Passenger Warning 36 Operation Warning 33 Passenger Warning 36 Rack Warning 37 Tire Pressure Warning 35 Safety Labels and Locations 32 38 Safety Training
8. 90cc Models 08 12 2 3 mm 08 12 2 3 mm 129 Maintenance Brake Freeplay Front Brake Adjustment 1 Position the vehicle on a level surface 2 Shiftthe transmission to neutral 3 Elevate the front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground Front Brake 4 While rotating the eft front wheel Adjuster Nuts tighten the upper front brake adjuster nut on the right hand control 5 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 130 Maintenance Brake Freeplay Front Brake Adjustment 6 While rotating the right front wheel tighten the lower 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 129 10 Carefully lower the vehicle to the ground 131 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
9. Rear Brakes 8 Front Brakes 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 stop 9 Ignition Switch 9 Ignition Switch 10 Tether Switch 2 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 45 Know Your ATV Let s review the three ways to stop the engine of your ATV Push the engine stop switch down 2 Pullthe tether strap off the ATV 3 Turn the key off 46 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 1 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 stick
10. grass weeds brush and other tall ground cover Promptly remove any grass or debris clinging to the vehicle Safety European Vibration and Noise The driver perceived noise and hand arm and whole body vibration levels of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature 31 Safety Safety Labels and Locations Warning labels have been placed on the vehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Age Warning WARNING Operation of this ATV by children under age 10 increases the risk of s
11. 4 4 4 4 4 4 4 4 qo Main Je 82 82 82 82 80 80 80 80 Pilot Je 42 42 40 40 40 40 40 40 2000 4000 Glip Position 4 4 4 4 4 4 4 4 mons Main Je 82 82 82 82 80 80 80 80 5 Pilot Je 42 42 40 40 40 40 40 40 4000 6000 Position 4 4 4 4 4 4 4 4 82 82 82 82 80 80 80 80 d Pilot Je 42 42 40 40 40 40 40 40 6000 8000 Glip Position 4 4 4 4 4 4 4 4 2400 3000 Main 80 80 80 80 78 78 78 78 8000 10000 Pilot 42 42 40 40 40 40 40 40 Clip Position 4 4 4 4 4 4 4 4 3000 3700 Main Je 80 80 80 80 78 78 78 78 10000 12000 Pilot Je 42 42 40 40 40 40 40 40 Clip Position 4 4 4 4 4 4 4 4 The carburetor jetting chart above is consistent with the provisions of U S A federal regulation 40 CFR 1051 115 d 3 167 POLARIS Products Part Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 1 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid qt 95 1 2878069 AGL Full Synthetic Gearcase Lubricant amp Transmission Fluid gal 3 8 1 2872348 Chain Lube Aerosol 168 POLARIS Products Part Number Description Grease 2871322 All Season Grease 3 0z 89 ml 2871423 All Season Grease 14 0z 414 ml Mi
12. 6 Perform the following maintenance at the end of the break in period Item End of Break In Remarks See Page Engine oil change Perform break in oil change 110 Oil pre filter screen Clean filter with oil change 111 114 Perform break in oil change See your dealer for inspection and adjustment Transmission oil Valve clearance 71 Operation Pre Ride Inspection Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Pre Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 129 133 Front suspension Inspect lubricate if necessary 106 Rear suspension Inspect lubricate if necessary 106 Steering Ensure free operation lubricate if necessary 134 136 Tires Check condition and pressure 143 Wheels fasteners Inspect ensure fastener tightness check that 145 146 axle nuts are secured by cotter pins Fuel and oil Check and fill as needed 15 66 72 Pre Ride Inspection Operation Pre Ride Checklist Item Remarks Page Throttle Check for proper operation 47 60 61 Engine stop switch Check for proper function 58 Daytime running lights if equipped Check for proper operation 149 Brakelight Check for proper operation 147 Air filter pre filte
13. Fuel filter 100 12M 1000 1600 Change filter 113 Engine mounts 100 12M 1000 1600 Inspect Exhaust 100 12 1000 1600 Inspect D Ignition timing 100 12M 1000 1600 Inspect gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 104 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Wiring 100 12M 1000 1600 Inspect for wear routing security apply dielectric grease to tors subjected to water mud etc D Clutches drive and driven 100 12M 1000 1600 Inspect clean replace worn parts Front wheel bearings 100 12M 1000 1600 Inspect replace as needed Spark arrester 300 36M 3000 4800 Clean out 122 D Toe adjustment Inspect periodically adjust when 134 parts are replaced 105 Maintenance Lubrication Guide Transmission Oil Level Transmission Fluid Item Lube Method Engine Oil PS 4 Extreme Duty See page 108 10W 50 4 Cycle Oil Gearcase AGL Gearcase Lubricant amp See page 114 Drive Chain POLARIS Chain Lube or SAE 80 90 See page 137 gt Front Suspension A Arm POLARIS All Season Grease or grease conforming to NLGI No 2 Inspect tighten
14. Horn Button 3 Throttle Control 41 Know Your ATV 4 42 Kick Start Lever If your battery is 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 68 5 Shift Lever Shift Lever The shift lever is on the right side of your ATV Read about how to use the shift lever on page 62 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 43 Know Your ATV 8 Brake Levers Squeeze the brake levers toward the handlebar to slow down or stop the AT V 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
15. Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase 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 your proof of warranty coverage 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 VEHICLE IS REGISTERED WITH POLARIS Initial deale
16. Warnings Operating at Excessive Speeds Physical Control of the ATV Operating the ATV at excessive speeds Removing a hand from the handlebars or feet increases the operator s risk of losing control from the footrests during operation can reduce Always operate at a speed that s appropriate for your ability to control the vehicle or cause loss of the terrain the visibility and operating conditions balance and ejection from the ATV If the and your experience operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests 19 Safety Safety Warnings Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds 20 Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving 4 A S 22 D Safety Safety Warnings Improper Hill Climbing Operating on Steep Hills Improper hill climbing could cause loss of control Operating on excessively steep hills could cause or overturn Always follow proper
17. carburetor bowl m 158 Maintenance Storage Engine Oil Change the oil See page 110 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 98 Transmission Oil Engine Oil Brake Fluid 159 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main tenance Chart beginning on page 98 Storage Area Covers 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 Coverthe vehicle with an appropriate cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 160 Maintenance Transporting the ATV 1 Stop the engine Place the transmission in gear Lock the parking brake 2 Secure the fuel cap oil cap and seat Turn the fuel valve off NOTICE Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting 3 Wrap the front tie strap through the frame tubes not through the bumper tube
18. 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 performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck f gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the ATV is stored or parked See page 67 Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area 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 15 Safety Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 16 Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident Operating without eye protection could result i
19. check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding 27 Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast flowing water could cause the tires to float causing loss of control or overturn Avoid operating through deep or fast flowing water If it s unavoidable to enter water that exceeds the height of the footrests Travel slowly Balance your weight carefully Avoid 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 After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads 28 Safety Warnings Improper Cargo Loading Overloading the ATV or carrying towing cargo may cause changes in handling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes or steering T
20. exhaust emissions beyond their legal limits will void all man ufacturer 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 the EMC requirements of European directives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 97 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 191 98 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 Service and adjustments are critical If you re not familiar with safe service and adjustment procedur
21. fasteners grease also after washing ATV or driving in water gt Perform these procedures more often for vehicles subjected to severe use 106 Maintenance Lubrication Guide QS qM Grease Points ALS Grease Points 107 Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98 POLARIS recommends the use of POLARIS PS 4 Extreme Duty 4 Cycle engine oil for this vehicle Oil may need to be changed more frequently if POLARIS oil is not used Do not use automotive oil See page 168 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 108 Engine Oil Check Maintain the oil level within the safe range on the dipstick Do not overfill 1 2 3 4 Position the vehicle on a level surface Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather 3 6 driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immedi ately Add the recommended oil as needed Reinstall the dipstick Maintenance Safe Range
22. filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98 Do not attempt to clean the fuel filter 113 Maintenance Transmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of the 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 98 POLARIS recommends the use of AGL Gearcase Lubricant amp Transmis sion Fluid See page 168 for the part numbers of POLARIS products Position the vehicle on a level surface Drain Plug 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 eA gt 114 Maintenance Transmission Oil Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the gearcase 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Addthe recommended oil Maintain the oil level at the bottom of the fill plug hole threads 7 Reinstall the fill plug Check for leaks 8 Dispose of used oil properly Gearcase Capacity OUTLAW 90 11 8 oz 350 ml SPORTSMAN 90 11 8 oz 350 ml 115 Maintenance Spark Pl
23. installed and properly routed to the throttle control 61 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 moving 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 NOTICE Do not attempt to shift 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 62 Shift Lever 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 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 Rear Brakes Front Brakes 63 Features and Controls Brakes Parking Brake Not Locked 1 Squeeze the left brake lever 2 Pushthe parking brake lock down to lock the brake lever in place 3 Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever The parking brake will release automatically 5 Always lock the parking brake whenever the vehicle is left una
24. loosen the wing nut one full turn 6 Verify that the left hand brake functions correctly 7 Verify that brake lever freeplay is at specification See page 129 8 Carefully lower the vehicle to the ground 132 pea seii DOLI LL Rear Brake Wing Nut Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 98 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 133 Maintenance Toe Alignment Use the following procedure to check the toe align ment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out 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 Position the vehicle on a level surface
25. of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 190 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 INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 10 Hours Break in 40 Hours 50 Hours 80 Hours 191 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 100 Hours 120 Hours 150 Hours 192 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 193 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 194 A Age Restrictions 13 Air Filter 140 141 Axle and Wheel Nuts 146 B Battery 150 153 Installation Connections 152 Removal iuris vua 151 StOrage ssc sc es ees 133 157 BOO S aed e aede ddr Dac de cio 11 Brake Adjustment Front 130 131 Brak
26. on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 82 Operation Driving on Slippery Surfaces 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Sideways skid Turn in direction of skid Osa D DSA 4 L A T T 4 D O Ned x D 83 Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 15 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 15 Maximum 84 Operation Driving Uphill 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a steady rate of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 9 Remain alert and be prepared to take emergency action This may include quick dis mounting of the vehic
27. outlined in the safety section of this owner s manual 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 NOTICE 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 69 Operation Break in Period 1 the fuel tank with gasoline Always exercise extreme caution whenever handling gasoline See page 15 2 Check the oil level Add the recommended oil as needed Maintain the oil level in the proper range See page 109 3 Drive slowly at first Select an open area that allows room to familiarize yourself with operation and handling 4 Vary throttle positions Do not operate at sustained idle 70 Operation Break in Period 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 72
28. the selling dealer s authorized location This policy does not apply to Safety Bulletins 183 Warranty EXPORTED PRODUCTS NOTICE If Purchased From A Private Party If your product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at POLARIS This warranty gives you specific legal rights and you may also have other rights which vary from state to state or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 184 Warranty U S A EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped
29. 73 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 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 174 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 air filter Inspect and clean or replace Electronic throttle control malfunction See your POLARIS dealer Other mechanical failure See your POLARIS dealer 175 Warranty LIMITED WARRANTY POLARIS Sales
30. For your child s safety be sure your child can reach and operate all ATV controls including handlebars brake levers throttle lever and engine stop switch Always follow the age guidelines for your vehicle 10 90cc models are designed for children not less than 10 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 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Safety Safety Training safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new POLARIS ATV in the United States your dealer provided information about the authorized ATV RiderCourse that is available to you and your eligible family members This training 1s included in the purchase price of your AT V In addition you were provided with printed material and a video or DVD that instructs operators on safe operating procedures You should review this information with your child on a regular basis 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 safety training course Safety Training If you purc
31. IS ATV there are some important things that you need to know You must learn how to keep yourself and those around you safe while you re riding 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 You must also take an ATV training course before you begin riding 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 Never drive your ATV alone Always make sure an adult is watching you when you ride Drive safely and enjoy riding your new POLARIS ATV Introduction 6 Safety iac micro E ae dia 8 Youth Section 39 Know Your ATV 40 Pre Ride Check 47 Riding Rules 50 Table of Contents Adult Section 55 Vehicle ID Numbers 56 Features and Controls 57 Operation 69 Emission Control Systems 96 Maintenance 98 Specifications 162 POLARIS Products 168 Troubleshooting 170 Warranty 176 Maintenance Log 191 Index asus rwn nnn 195 Introduction Safety Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these word
32. LARIS repair or replacement of any defective materials components or products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE 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 188 Warranty U S A EPA Emissions Limited Warranty 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 when the vehicle has been used in racing competition This limited warranty also does n
33. LARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 171 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 172 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 Electronic throttle control malfunction See your POLARIS dealer Other mechanical failure See your POLARIS dealer 1
34. Pantone 419C Owner s Manual for Maintenance and Safety OUTLAW 90 m SPORTSMAN 90 Read this manual carefully It contains important safety information Adult supervision is required at all times Operation is prohibited for anyone under 10 A WARNING 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 polaris com POLARIS POLARISG SPORTSMAN and OUTLAW are registered trademarks of POLARIS Industries Inc Copyright 2013 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 contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in E
35. RIS 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 over the ankle boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection Safety Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed WARNING Modifying this vehicle in any way can change the top speed stability and handling performance of this vehicle Modifications that increase speed decrease stability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death Use only POLARIS approved accessories to modify this vehicle Review all vehicle changes with your child prior to operating The warranty on your POLARIS vehicle will be terminated if any non POLARIS approved equipment and or modifications have been added to the vehicle that increase speed or power 12 Safety Safety Warnings AWARNING Failure to operate the ATV properly can result in a collision loss of control accident o
36. The recommended maximum depth for your ATV is below the bottom of the footrests Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 If crossing a stream choose a crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water 92 Operation Driving Through Water 4 After driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes may be ineffective NOTICE Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footrest level As soon as possible perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 98 Engine oil gearcase oil front and rear gearcases if equipped and all grease fittings need special attention If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 118 then see your dealer for service at the first opportunity 93 Operation Hauling Cargo The SPORTSMAN 90 was designed with racks to carry small loads R
37. always be watching you in case you need help Always drive within the sight of an adult gt Never ride on public trails gt Don t ride your on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you gt Don t ride at night Your ATV doesn t have lights that are safe for driving in the dark gt Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them gt Never ride on frozen water You could get hurt or you could even die All ice can be dan gerous gt 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 gt Always be a polite driver Don t drive through the flower garden or over the little trees you planted gt Always do your best to help take care of nature 53 54 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new POLARIS ATV Vehicle Identification Numbers Record your ATV s identification num Engine Serial Number bers and key number in the spaces pro AG vided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS EEL SANV key blank using your key number and gt lt NA i mating it with one of your existing keys poe The ignition switch must be repla
38. c surfaces Do not allow these types of products to contact the vehicle 153 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 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 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 154 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 Wheel bearings Brakes Radiator Cab and body panels Transmission seals Labels and decals If warning and safety labels are damaged contact your POLARIS dealer for free replace ment Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 155 Maintenance Polishing POLARIS recommends the use of
39. ced if NA f RJ all keys are lost ee 2 7 XE gt Vehicle Model Number Frame VIN Engine Serial Number Key Number on the key 56 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 Always remove the ignition key when the vehicle is not in use 2 OUTLAW SPORTSMAN 57 Features and Controls Engine 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 means of engine shutdown in case of stuck throttle or other emergency Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Horn Stop Switch 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 58 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 Follow the Starting the Engine procedure beginning on page 76 59 Features and Cont
40. common household aerosol furniture polish for polishing the finish on your POLARIS vehicle Follow the instructions on the container Polishing Tips the use of automotive products some of which can scratch the finish of your vehi cle 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 156 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended See page 153 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 157 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 pro motes better starting after the storage period Fillthe fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stopthe engine Turn the fuel valve off 6 Drain the
41. documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product 182 Warranty EXPORTED PRODUCTS EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of
42. e Adjustment Rear 132 Brake Freeplay 129 132 Brake Freeplay Specifications 129 Brake Lever Travel 133 Brake 44 Brake Parking 64 Brakes bosse Run ds 63 64 Break in Period 69 71 C Camber and Caster 136 Carburetor i noe 124 125 Carburetor Jetting OUTLAW 90 164 SPORTSMAN 90 167 Constant Variable Transmission Consumer Product Safety Cylinder Head Torque Daytime Running Lights Drive Chain Slack Drive Chain Slack Adjustment Driving Downhill Driving in Reverse Driving on a Sidehill Driving on Slippery Surfaces Driving Over Obstacles Driving Procedure Driving Through Water Driving Uphill Index E Electronic Throttle Control 61 Emission Control Systems 96 97 Engine Start Button 59 Engine Stop Switch 58 Equipment Modifications 12 Exhaust Exposure to 15 Eye Protection 11 F Fuel Filter sassy oer 113 Fuel Safety 15 Fuel Stabilizer 158 Fuel System ee mee 66 Fuel Valve eger ee tete 67 G Gas Capi 43 66 Gasoline Handling 15 Gearcase Capacity 115 Gloves ber beet 11 195 Index H Handlebar Adjustment 142 Hauling Care 94 95 SIM GE ace de 10 zio ae onis 59 Horn Button 41
43. e is found 4 Reinstall the arrester 5 Torque the bolts to 7 ft Ibs 9 5 Nm 123 Maintenance Carburetor Your POLARIS is calibrated at the factory for optimal performance at altitudes ranging from zero to 8 000 feet 2400 m and temperatures above 15 F 9 C Refer to the specifi cations section beginning on page 162 for carburetor and jetting specifications Any jetting changes must be made only by an authorized POLARIS dealer Always see your dealer if jetting changes are needed 124 Maintenance Carburetor If engine idle speed is too high the vehicle will creep If idle speed is too low the engine will stall To adjust idle speed do the following 1 2 3 4 Lock the parking brake Start the engine Allow the engine to warm up for approximately five minutes Adjust the carburetor idle screw either in or out until the desired idle speed is reached Turning the screw in clockwise will increase idle speed Turning the screw out coun ter clockwise will decrease idle speed Tip If using an RPM gauge the factory idle speed setting for 90cc models is 1700 100 RPM 125 Maintenance Speed Control System Per ANSI SVIA 1 2010 sec 6 2 AS DELIVERED TO THE CONSUMER the speed of youth models is restricted to 10 MPH or less for the 50cc Y 6 models and 15 MPH or less for the 90cc 10 models The dealer CANNOT under any circumstances either prior to the sale or later even at the con
44. e more often under severe use such as in dirty or wet conditions See page 168 for the part numbers of POLARIS products NOTICE 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 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 specifications 137 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 use the procedure on page 139 138 Chain Tensioner Drive Chain Slack Adjustment 1 2 3 Loosen the four rear housing mount bolts Loosen the chain adjuster lock nut Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection Tighten the chain adjuster loc
45. e the rear brake lever and press the starter button The rear brake lever must be engaged or the engine won t start 9 Do not press the throttle while starting the engine 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 77 Operation Stopping the Engine 1 Release the throttle completely 2 Apply the brakes until the vehicle stops moving 3 Shiftthe transmission to neutral 4 Stop the engine There are three ways to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV 5 Lock the parking brake 6 To avoid draining the battery always turn the key to the OFF position when the engine is not running 78 Operation Driving Procedure 1 gt tA nz Sit upright with both feet on the footrests and both hands on the handlebars Shift the transmission to neutral Start the engine and allow it to warm up Check your surroundings and determine your path of travel Squeeze the left brake lever Shift the transmission to the des
46. ead and follow all of the instructions for hauling cargo on the following pages Never carry cargo on the OUT LAW 90 AWARNING Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control which can result in serious injury or death Always follow these precautions when hauling cargo 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 94 Operation Hauling Cargo Never exceed the weight capacities for the vehicle Capacities are listed in the specifications section beginning on page 162 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 95 Emission Control Systems Noise Emission Control System Do not modify the engine intake or exhaus
47. ed into the transmission follow the procedure on page 121 for drying the CVT Maintenance Drain Screw 119 Maintenance Constant Variable Transmission CVT System AWARNING 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 modification 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 However 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 prod uct Always make sure the CVT housing is securely in place during operation 120 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 4 5 6 Remove the drain plug Allow the water to drain Reins
48. eration RES For reserve supply if main supply is exhausted 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 posi tion after refueling SPORTSMAN 90 Fuel Valve Features and Controls Fuel Valve o 67 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 Shiftthe transmission to neutral 3 Lock the parking brake 4 Fold out the kick start lever on the left side of the ATV Tip A 10 12mm wrench 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 Turn the fuel valve on Push the engine stop switch up to the ON position Turn the key to ON Place your foot on the kick start then thrust your heel downward to crank the engine 9 After the engine has started fold the kick start lever back into place tA 68 Kick Start Lever Operation AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings
49. es have a qualified dealer perform these operations Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation 99 Maintenance Periodic Maintenance Chart Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use such as in dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical com ponents E Emission related service failure to conduct this maintenance will not void the emissions war ranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and cause an accident which may result in serious injury or death Always have an authorized POLARIS dealer perform these services 100 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Miles Km Page Steering Daily Check each day before operating 72 Fron suspension ted P de Ghost Rear suspension Daily list Tires 5 Daily Brake lever travel E Daily ER Brake system Daily Wheels fasteners Daily Frame fasteners Daily
50. evere injury or death Adult supervision required for children under age 16 NEVER permit children under age 10 to operate this ATV 32 Safety Safety Labels and Locations 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 passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 33 Safety Safety Labels and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 34 Safety Labels and Locations Tire Pressure Warning OUTLAW 90 WARNING Improper tire pressure or overloading can cause loss of contro
51. hased a used POLARIS ATV in the United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for infor mation about safety training Safety FOR MORE INFORMATION ABOUT ATV SAFETY in the United States call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call POLARIS at 1 800 342 3764 Safety 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 stan dards 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 surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label 10 Long Helmet Sleeves 051039 0006 31 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLA
52. he object may overturn or collide with other objects Never exceed the stated load capacity for this ATV 29 Safety Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Operating a Damaged ATV Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 30 Physical Skills 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 overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust System components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Always inspect the underside of the ATV after driving through tall
53. he parking 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 nM 88 Operation Turning Around on a Hill 7 Lock the parking brake and remount the from the uphill side keeping body weight uphill 8 Restart the engine 9 Squeeze the rear brake lever 10 Shift the transmission to forward gear 11 Release the parking brake and drive slowly controlling speed with the rear brake until the is on more level ground 89 Operation Parking on a Hill or Incline Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Stop the engine 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 90 Operation Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operat ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obsta cles such as rocks or fallen trees 91 Operation Driving Through Water Your ATV can safely operate through shallow water
54. ice you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration From 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 In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair 181 Warranty HOW TO OBTAIN WARRANTY 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 Product importation rules vary considerably from country to country You may be required to present
55. il on their own An adult should always be in charge of keeping the gas and oil levels at the full marks 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 46 and review Then have an adult help you start the engine Practice stop ping the engine all three ways 49 Riding Rules Now you re ready to learn about riding your POLARIS There are some things you can do and there are some things you must never do Rules are very important when you re driv ing 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 50 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 w
56. ind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy over the ankle 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 Helmet Sleeves Long Pants you shift your weight If it s too big it could hang down and get caught in a moving part Wear long sleeves and long pants to protect your arms and legs 51 Riding Rules gt Always attach the tether strap to your right wrist and to the ATV before riding gt 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 gt Your is made for one person Never carry a passenger A passenger will make the ATV harder to drive You may lose control and hurt yourself and your passenger gt Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests gt 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 gt Never follow another too closely You need lots of time and space to stop your gt Never tow or pull an object behind the 52 Riding Rules gt Never ride alone An adult should
57. ing 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 151 Maintenance Battery Battery Installation and Connections Always install a fully charged battery 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 Set the battery in its holder Coat the terminals with dielectric grease or petroleum jelly 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 152 Maintenance Battery 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 Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components POLARIS recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plasti
58. ired gear Slowly release the brake lever Slowly press the throttle with your right thumb and begin driving Drive slowly at first Practice turning and using the throttle and brakes on level surfaces 79 Operation Making Turns Your 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 alters the balance of traction between the rear wheels allowing the turn to be made smoothly Practice making turns at slow speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 80 Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly PWN Operation 81 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate
59. k nut to 18 ft Ibs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid breaking the stud Tighten the four rear housing mount bolts to 43 ft Ibs 60 Nm Maintenance i i Housin Mount Chain Adjuster Bolts 139 Maintenance Air Filter Remove the seat See page 43 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 a commercially available foam filter lubricant to the foam filter Support Screen 140 Maintenance Air Filter 5 Clean away any oil or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat NOTICE Never operate the ATV with the filter element removed Dirt will enter the engine causing rapid wear and severe damage to the engine 141 Maintenance Handlebar Adjustment AWARNING 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 handlebars can be adjusted for rider preference 1 Remove the pod to access the handlebar bolts Loosen
60. ks whichever comes first Hours Calendar Miles Km SER Battery 20 Monthly 200 320 Check terminals clean test 150 gt Engine oil change 30 6M 300 480 Drain and change the oil 110 gt Transmission oil 40 12M 400 640 Drain and change the oil 114 gt Oil pre filter screen 40 12M 400 640 Clean filter at every oil change 111 clean annually if ATV is operated less than 10 hours gt General lubrication 50 3M 500 800 Lubricate all fittings pivots cables etc D 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 D Throttle cable ETC switch 50 6M 500 800 Inspect adjust lubricate replace if necessary D Choke cable 50 6M 500 800 Inspect adjust lubricate replace if necessary Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first See Hours Calendar Miles Km Page E Carburetor air intake 50 6M 500 800 Check for proper sealing air leaks ducts flange D Drive belt 50 6M 500 800 See your POLARIS dealer 50 6M 500 800 See your POLARIS dealer D Fuel system 100 12M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carbure tor replace lines every two years E
61. l Loss of control can result in severe injury or death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa e Maximum Weight Capacity 180 Ibs 81 7 kg Tire Pressure Warning SPORTSMAN 90 WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa e Maximum Weight Capacity 225 Ibs 102 kg 35 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause loss of control resulting in SEVERE INJURY or DEATH 36 Safety Labels and Locations SPORTSMAN 90 Rack Warning WARNING DO NOT TOW Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 Ibs 7 kg Rear 30 Ibs 14 kg 37 Safety Safety Labels and Locations Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To pre vent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 38 Youth Section Know Your ATV PARENTS POLARIS Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle f
62. le 85 Operation Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keeping your feet on the footrests 3 Ifthe vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 86 Operation Driving Downhill When driving downhill follow these precau tions 1 Avoid steep hills 15 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when trav eling downhill can cause loss of control 5 Apply the front and rear brakes at the same time and very slightly to aid in slowing 87 Operation Turning Around on a Hill If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Stop the vehicle and lock the parking brake while keeping body weight uphill 2 Shiftthe transmission to neutral 3 Shutoff the engine 4 UE on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the ATV turn the handlebars full left While holding the brake release t
63. n an accident and could increase the chance of a serious injury in the event of an accident Always wear 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 Safety Safety Warnings Carrying a Passenger Using Alcohol or Drugs Carrying a passenger greatly reduces the Operating the ATV after consuming alcohol or operator s ability to balance and control the ATV drugs could adversely affect operator judgment which may result in an accident or overturn reaction time balance and perception Never Never carry a passenger on this ATV consume alcohol or drugs before or while operating an ATV 17 Safety Safety Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops 18 Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Safety Safety
64. nglish Other languages are provided as translations of the original instructions Printed in Taiwan 2014 OUTLAW 90 SPORTSMAN 90 Owner s Manual P N 9924620 Welcome Dear Parents We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you We ve provided this owner s manual to assist you and your children in learning about safe operation and care of your new ATV A POLARIS ATV is not a toy and can be hazardous to operate Make sure any child who will operate the ATV takes a training course before operating the ATV Make sure all operators understand and follow all of the instructions and warnings contained in this owner s manual Never allow a child under the age of 16 to operate an ATV without adult supervision Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely For your child s safety be sure your child can reach and operate all ATV controls including handlebars brake levers throttle lever and engine stop switch 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 specific intervals Follow all of the instructions and recommendations in this manual Welcome Dear Children Before you ride your new POLAR
65. ntrol of the ATV 19 Starting the Engine 76 77 Transporting the ATV 161 Physical Skills 30 Steering Inspection 136 Turning Around on a Hill 88 89 Protective Apparel 16 Stop Switch cere 58 Skidding or Sliding 27 Stopping the ed V Slippery Terrain 4 29 Stopping the Engine Vehicle Identification Numbers 56 Stalling While Climbing a Hill 24 SIONALE vea a d 157 160 Vehicle Immersion 118 119 Turning Improperly 20 Switches Unauthorized Use of the ATV 30 Engine Start Button 59 Unfamiliar Terrain 26 Engine Stop Switch 41 58 Washing the ATV 154 Using Alcohol or Drugs 17 Horn Button eer 41 Whe lH b Ti OE 146 Safety Words and Symbols 6 Ignition Switch 45 Wheel I e ila uc ELE 145 Seat Latchiz sete 43 Main Key Switch 57 Wheel NO 146 Severe USE 99 Tether Switch i e 45 Wheel Re oe Rete ere 144 Shift Lever iioii eee 42 62 fece AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE AN APPROVED ON PUBLIC HELMET AND ROADS PROTECTIVE GEAR NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 41 1 NEVER operate without proper training or instruction at speeds too fa
66. olts to 22 ft Ibs 30 Nm 145 Maintenance Axle and Wheel Nuts 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 service must be performed by your authorized POLARIS dealer 146 Maintenance Tail Light Lamp Replacement If the brakelight doesn t work the lamp may Lamp 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 147 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 148 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 from your authorized POLARIS dealer 1 2 3 4 nM Remove the front cab OUTLAW only Disconnect the lights from the harness Remove the rubber cover from the back of the light assembly Pres
67. or the rider s skill and experience More information on speed limiting functions can be found beginning on page 126 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 162 for your ATV s capacity CHILDREN Before you ride your new POLARIS ATV there are some important things that you need to know 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 Pay attention when you see this symbol means PAY ATTENTION because you could die or be seriously injured if you don t follow the This is the safety alert symbol When you see this symbol on your ATV or in this manual it A instructions 40 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 47 2
68. ot cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only Pure POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law 189 Warranty U S A EPA Emissions Limited Warranty California Residents Certain POLARIS off road vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation
69. ould cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost If you lose all forward speed Keep 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 the ATV begins rolling downhill 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 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 88 24 Safety Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 29 Safety Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel
70. procedures for an overturn Never operate on hills too steep for climbing hills as described in the owner s the ATV or for your abilities Never operate the manual See page 84 ATV on hills steeper than 15 degrees 21 Safety Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 87 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 22 Safety Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 86 Never attempt 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 88 23 Safety Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill c
71. r Inspect clean or replace 140 Drive chain Check condition and slack refer to drive 137 chain adjustment Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any damaged compo nents or loose fasteners Riding gear Wear helmet goggles protective clothing 10 73 Operation Safe Operation Practices 1 74 Complete the recommended safety training before operating this vehicle See page 8 Do not allow anyone under age 10 to operate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Never exceed the maximum weight capacity of the vehicle When determin ing the weight you are adding to the vehicle include the weight of the opera tor accessories and loads on the racks if equipped The combined weight of these items must not exceed the maxi mum weight capacity Safe Operation Practices 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the han dlebars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an
72. r overturn which may result in serious injury or death 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 hazards outlined in this section of the owner s manual MUST be avoided at all times See the RIDING RULES section and the OPERATION section of the owner s manual for proper operating procedures Operator Restrictions Age Restrictions This vehicle is for recreational use by young operators under adult supervision ONLY Operation is prohibited for anyone under age 10 13 Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete an ATV training course They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual See page 8 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course 14 Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions Never allow a child to refuel or handle gasoline Always exercise extreme
73. r preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 176 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 177 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This war
74. ranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses e o e o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filter Sealants Lubricants Coolants Bushings Bearings 178 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of p
75. rofits or loss of vacation or personal time 179 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 180 Warranty HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty serv
76. rols Throttle Controls AWARNING 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 result in an accident if the throt tle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation 60 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 WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the ETC system or replace it with any after market throttle mechanism Always ensure that the throttle cable is
77. s and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following systems Air induction system Ignition system Fuel system Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions Aftertreatment devices Sensors Crankcase ventilation valves Electronic control units 186 Warranty U S A EPA Emissions Limited Warranty The following parts are considered emission related components for evaporative emissions Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls e o Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Vapor Hoses Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector As related to the evaporative emission control system 187 Warranty U S A EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be at the exclusive option of PO
78. s or attach a tie down hook around each of the tubes 4 Wrap the rear tie strap around the grab bar Specifications OUTLAW 90 Rider Capacity Maximum Weight 1 Rider 180 165 81 7 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 Front Rear Brakes Drum Parking Brake Mechanical Lock Front Tires 19 x 7 8 8 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa 162 Specifications OUTLAW 90 Dry Weight 270 lbs 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 Carburetor Settings Cutaway n a Pilot Air Screw 1 25 turns out Needle Jet 11 Pilot Jet 40 Main Jet 80 E Clip Position 4 from top 163 Specifications OUTLAW 90 Carburetor Jetting Shaded cells indica
79. s and symbols are used Become familiar with their meanings before reading the manual A CAUTION A CAUTION indicates a hazardous situation The safety alert symbol indicates a potential which if not avoided could result in minor or personal injury hazard ot DANGER moderate injury NOTICE A DANGER indicates a hazardous situation that A NOTICE indicates a situation that could result if not avoided will result in death or serious in property damage injury WARNING The Prohibition Safety Sign indicates A WARNING indicates a hazardous situation an action NOT to take in order to avoid which if not avoided could result in death or a hazard serious injury The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard AWARNING Introduction Failure to follow the warnings and safety precautions contained 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 driving on hills or over obstacles if you fail to take proper precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course
80. s 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 149 Maintenance Battery AWARNING 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 always connect the negative black cable last The battery in your POLARIS 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 to reduce oxidation and excessive power consumption 150 Maintenance Battery Battery Removal 1 2 3 4 Disconnect the hold down straps secur
81. scellaneous Additives 2871326 Carbon Clean 169 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 Old or non recommended fuel Turn the fuel valve on 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 Low battery voltage Replace the filter Recharge battery with 5 amp charger Mechanical failure See your POLARIS dealer 170 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 Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your PO
82. slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 26 Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 81 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Safety Warnings Improper Vehicle Modifications Improper installation of accessories or modification of the ATV may cause changes in handling which could cause loss of control or an accident 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 See your authorized POLARIS ATV dealer for more information Safety Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area
83. so it conforms with applicable U S Environmental Protection Agency emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc or greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension 185 Warranty U S A EPA Emissions Limited Warranty This emissions limited warranty covers components whose failure increases the vehicle s regulated emission
84. st for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control For your nearest Polaris dealer call 1 800 POLARIS POLARIS or visit www polaris com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9924620 Rev 01 Printed in Taiwan EIU EE AU A UH NT I I I EI UE UM
85. sumer s request remove or adjust any speed limiting devices Your POLARIS ATV has an adjustable throttle limiting screw Speed limiting devices may be adjusted removed only by consumers when they determine that their child is capable of handling the additional speed Per ANSI SVIA 1 2010 sec 6 1 the unrestricted top speed is 15 MPH or less for the 50cc Y 6 models and 30 MPH or less for the 90cc Y 10 models 126 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 Jam Nut Maintenance 127 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 128 Nut 1 16 1 8 1 5 3 2 mm Brake Freeplay Check measure the freeplay of the front and rear brakes at the intervals rec ommended in the Periodic Maintenance Chart beginning on page 98 If the free play isn t at specification adjust the freeplay as outlined on the following pages Maintenance eee Freeplay Brake Freeplay Specifications Model Front Brake Rear Brake
86. t components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS stan dard 5100 1c Federal law requires that this spark arrester 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 420 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 cham ber by the intake system All exhaust gases exit through the exhaust system 96 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 maintained at POLARIS specifications to achieve opti mal performance Engine idle speed is the only adjustment POLARIS recommends that the operator perform Any other adjust ments should be performed by an authorized POLARIS dealer The emissions label is located on the clutch cover or engine case near the clutch box The installation of devices that effectively increase
87. tall 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 NOTICE Exposure to salt water will cause corrosion to metal components If your vehicle is operated in salt water areas rinse it off frequently with fresh water 121 Maintenance Spark Arrester To remove accumulated carbon clean the spark arrester at the intervals recommended in the Periodic Maintenance Chart beginning on page 98 AWARNING Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrester while the system is hot Allow components to cool suffi ciently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas 122 Maintenance Spark Arrester Remove the six bolts and remove the arrester from the end of the muffler 2 Usea non synthetic brush to clean the arrester 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 arrester if damag
88. te factory settings AMBIENT TEMPERATURE Meters Feet F Below 25 30to 10 15to 5 Oto 20 15to 35 30 to 50 45 to 65 Above 60 Below 35 34to 23 2610 15 1810 7 9to 2 1to 10 7to 18 Above 16 Main Je 82 82 82 82 80 80 80 80 2000 Pilot Je 42 42 40 40 40 40 40 40 Clip Position 4 4 4 4 4 4 4 4 mon Main Je 82 82 82 82 80 80 80 80 Pilot Je 42 42 40 40 40 40 40 40 2000 4000 Glip Position 4 4 4 4 4 4 4 4 SEN Main Je 82 82 82 82 80 80 80 80 5 Pilot Je 42 42 40 40 40 40 40 40 4000 6000 Position 4 4 4 4 4 4 4 4 mom Main Je 82 82 82 82 80 80 80 80 E Pilot Je 42 42 40 40 40 40 40 40 6000 8000 Position 4 4 4 4 4 4 4 4 2400 3000 Main 80 80 80 80 78 78 78 78 8000 10000 Pilot 42 42 40 40 40 40 40 40 Clip Position 4 4 4 4 4 4 4 4 3000 3700 Main Je 80 80 80 80 78 78 78 78 10000 12000 Pilot Je 42 42 40 40 40 40 40 40 Clip Position 4 4 4 4 4 4 4 4 The carburetor jetting chart above is consistent with the provisions of U S A federal regulation 40 CFR 1051 115 d 3 164 Specifications SPORTSMAN 90 Rider Capacity Maximum Weight 1 Rider 180 165 81 7 kg Displacement 89cc Cooling Air Cooled Engine 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
89. 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 165 10 Nm 142 Maintenance Tires AWARNING 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 Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires 143 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less al 1 8 8 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 144 Maintenance Wheel Installation 1 2 3 gt Lock the parking brake Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation Install the wheel bolts and finger tighten them Lower the vehicle to the ground Securely tighten the b
90. ttended 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 64 Features and Controls Lights AWARNING 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 visibility 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 65 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars Use POLARIS Carbon Clean fuel treatment at each fill Follow the mixing directions on the container See page 168 for the part numbers of POLARIS products Use unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Refer to the specifications section beginning on page 162 for fuel tank capacity 66 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 op
91. ug counterclock wise to remove it 3 Reverse the procedure for spark plug installation Torque to 14 ft lbs 19 Nm 117 Maintenance Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service or after 25 hours Vehicle Immersion If the vehicle tips or overturns in water deeper than the footrest level or if the engine stops during or after operating in water restarting WILL result in serious engine damage Trans port the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined below This proce dure will allow short term operation only to drive the ATV to a trailer or towing vehicle 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 118 Vehicle Immersion 5 6 7 8 9 10 11 12 Loosen the carburetor drain screw Turn the engine over several times using the electric start Dry the spark plug and reinstall it or replace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingest
92. ugs Refer to the specifications section beginning on page 162 for spark plug and gap specifica tions NOTICE Using non recommended spark plugs can result in serious engine damage Always use POLARIS recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should 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 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 116 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 The tip should not be white A white insulator tip indicates overheat ing caused by use of an improper spark plug or incorrect fuel system operation 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 fuel system operation Spark Plug Change Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark pl
93. y 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 47 Pre Ride Check 2 Make sure the brakes don t stick Check the brake levers by squeezing them toward the handlebar 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 iud sticky brakes Have an adult or your POLARIS dealer fix the sticky brakes before you ride 3 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 15 of this manual Always have an adult put gas in your ATV Never try to do it yourself 48 Pre Ride Check If you used the storage area under the seat make sure the seat is locked in place 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 o

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