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.
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
Welcome Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you. We've provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV. Please review the information in this manual with any child who may operate the ATV. Help your children learn to operate the ATV with safety as a top priority.
Welcome Dear Children: Before you ride your new Polaris ATV, there are some important things that you need to know. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner's manual. Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times.
Safety . . . . . . . . . . . . . . . . . . . . . . 6 Youth Section . . . . . . . . . . . . . . 17 Know Your ATV . . . . . . . . . . . 18 Pre-Ride Check . . . . . . . . . . . 25 Riding Rules . . . . . . . . . . . . . 28 Table of Contents Adult Section. . . . . . . . . . . . . . . 33 Safety Decals . . . . . . . . . . . . 34 Driver Warnings . . . . . . . . . . . 43 Vehicle ID Numbers. . . . . . . . 66 Features and Controls . . . . . . 67 Break-in Period . . . . . . . . . . . 83 Pre-Ride Inspections . . . . .
Safety Understand the Warnings Always follow the age guidelines for your ATV. Never allow a younger child to ride on or drive the ATV. Make sure all operators have completed an approved ATV safety training course such as the SVIA RiderCoursesm and understand all warnings and the owner's manual before driving the ATV. Know Your ATV Before Riding Parents must help their children learn the proper and safe way to ride an ATV.
Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm.
Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. CAUTION The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Safety WARNING Failure to follow the warnings in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand the owner's manual and all warnings before operating a Polaris ATV.
Safety • Read this manual and all labels carefully. Follow all operating procedures. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and age eligible family members are entitled to take the ATV RiderCoursesm. Contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.
Safety • Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. • Never consume alcohol or drugs before or while operating this ATV. • Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience. • Never attempt jumps or other stunts. • Never tow or pull an object behind the ATV.
Safety • Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. • Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
Safety • Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill. • Always use proper procedures if you stall or roll backwards when climbing a hill.
Safety • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Avoid operating the ATV through deep or fast flowing water.
Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
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Youth Section 17
Know Your ATV PARENTS: Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experience. More information on speed limiting functions can be found beginning on page 142. These units are not designed for adult use. Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section beginning on page 178 for your ATV's capacity.
Know Your ATV Before you have an adult start the engine for you for the first time, let's learn about the controls on your new ATV. 1. 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. 2. Horn Button - Press the horn button to sound the horn. 3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to go forward.
Know Your ATV 4. 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 82. 5. Shift Lever 5. Shift Lever - The shift lever is on the right side of your ATV. Read about how to use the shift lever on page 72. 4.
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 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.
Know Your ATV 8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured. Always take your thumb off the throttle lever when you squeeze the brake levers. 8. Rear Brakes 22 8.
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. 10. Tether Switch 9. Ignition Switch 9. Ignition Switch 10.
Know Your ATV Let's review the three ways to stop the engine of your ATV: 1. Push the engine stop switch down. 2. Pull the tether strap off the ATV. 3. Turn the key off.
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. n 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.
Pre-Ride Check n 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 with sticky brakes.
Pre-Ride Check n If you used the storage area under the seat, make sure the seat is locked in place. n Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been running and it can burn your skin if you touch it. Children must never check the oil on their own. An adult should always be in charge of keeping the gas and oil levels at the full marks. n This last check is done with the engine running.
Riding Rules Now you're ready to learn about riding your Polaris ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride. X 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.
Riding Rules X Always wear the right kind of clothing and safety gear when riding your ATV. Long Helmet Helmet: Your helmet is very important for safe riding. A Sleeves 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 Eye can see where you're driving. Protection Gloves Gloves: Wear gloves to protect your hands from sun and wind. Gloves will also protect your hands from scrapes Long Pants and scratches.
Riding Rules X Always attach the tether strap to your right wrist and to the ATV before riding. X 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. X Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder to drive. You may lose control and hurt yourself and your passenger. X Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on the footrests.
Riding Rules X Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. X Never ride on public trails. X Don't ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. X Don't ride at night. Your ATV doesn't have lights that are safe for driving in the dark. X Learn where there are lakes, rivers, ponds and ditches in your driving area.
Respect your ATV; respect your environment; and you will earn the respect of everyone.
Adult Section 33
Safety Decals Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge. The part number is printed on the decal.
Operation Warning Safety Decals 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.
Safety Decals Age Warning WARNING • Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing control, which could result in severe injury or death. • Adult supervision is required. • Make sure operators follow Owner's Manual and labels. • Make sure operators watch the safety video or DVD and complete the ATV RiderCoursesm. • Never operate this ATV on HILLS steeper than 15 degrees 15°. To prevent flipover on hilly terrain, use throttle and brakes gradually.
Outlaw 90 Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 453 LBS. (206 KG).
Safety Decals Sportsman 90 Tire Pressure Warning + WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 528 LBS. (240 KG). Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control.
No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
Safety Decals Sportsman 90 Rack Warning WARNING DO NOT TOW WITH THIS VEHICLE. Vehicle damage or tipover may result causing severe injury or death. Maximum Rack Loads: Front 15 lbs. (6.8 kg) Rear 30 lbs. (13.
Clutch Cover Warning Safety Decals WARNING NO STEP Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not touch clutch cover, cover may become hot. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.
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Driver Warnings Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child's safety. Be sure to explain to your young driver that the following hazards MUST be avoided at all times.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA.
Driver Warnings WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD Follow the age recommendations for this ATV.
Driver Warnings WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces your ability to balance and control this ATV. Carrying a passenger could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for passengers.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any paved or unpaved public street, road or highway. In many states it is illegal to operate ATVs on public streets, roads and highways.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV without wearing protective gear. WHAT CAN HAPPEN Operating without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection and protective clothing can also result in injury. HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Your judgment could be seriously affected. You may react more slowly. Your balance and perception will be affected. You could have an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
Driver Warnings WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Operating this ATV at excessive speeds. Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience.
Driver Warnings WARNING POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps, or other stunts. Avoid exhibition driving (don't show off).
Driver Warnings WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can make it harder to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may touch the rear wheels, which could injure you or cause an accident.
Driver Warnings WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. This could cause the ATV to overturn or go out of control. HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
Driver Warnings WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.
Driver Warnings WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner's manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed. 56 WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV.
Driver Warnings WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual beginning on page 98. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards.
Driver Warnings WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Driving downhill improperly could cause loss of control or ATV overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner's Manual. See page 104. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
Driver Warnings WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 102. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
Driver Warnings WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN: The ATV could overturn and cause injury. HOW TO AVOID THE HAZARD: Maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight uphill. Apply the front brakes gradually (right lever). When fully stopped, apply the rear brake as well (left lever) and then lock the parking brake. If you begin rolling backwards: Keep weight uphill.
Driver Warnings WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Skidding or sliding. Improperly operating over obstacles. WHAT CAN HAPPEN WHAT CAN HAPPEN Skidding or sliding can cause loss of control. Operating over obstacles could cause loss of control or overturn. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.
Driver Warnings WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Riding on frozen lakes and rivers. Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident.
Driver Warnings WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
Driver Warnings WARNING WARNING POTENTIAL HAZARD POTENTIAL HAZARD Overloading the ATV. Operating the ATV with improper modifications. WHAT CAN HAPPEN Overloading the ATV could cause changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. If equipped with racks, cargo should be properly distributed and securely attached.
Driver Warnings WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death. Do not allow disabled persons to operate this vehicle. WARNING Damaged components can cause loss of control resulting in serious injury or death.
Vehicle Identification Numbers Record your ATV's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. Key Key OUTLAW SPORTSMAN WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.
Features and Controls Engine Stop Switch Horn Stop Switch The engine will not start or run when the stop switch is down, in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle. To stop the engine quickly, push the stop switch down. Choke Lever Start Button Choke Lever Use the choke to start a cold engine.
Horn Button Features and Controls Use the horn for emergencies and to let others know you’re near. Engine Start Button The start button is located slightly above the choke lever 1. Attach the tether strap securely to the vehicle and to the rider's right wrist. 2. Shift the transmission to neutral. The neutral light will come on when the lever is in neutral. See page 77. 3. Turn the key to the ON position. 4. Lock the parking brake. 5. Push the engine stop switch up to the ON position. 6.
Features and Controls Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
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 stop and power to the rear wheels will cease.
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.
Features and Controls CAUTION 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. Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.
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. Front Brakes Rear 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.
Features and Controls Brakes Parking Brake 1. Squeeze the left brake lever. 2. Push the parking brake lock down to lock the brake lever in place. 3. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. Not Locked Locked 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.
Features and Controls Brakes Parking Brake 1. Always shift the transmission to neutral and lock the parking brake before starting the engine. 2. After the engine has warmed enough for operation, shift to the desired gear. 3. Release the parking brake and gently apply the throttle. 4. Always lock the parking brake whenever the vehicle is left unattended.
Features and Controls Lights WARNING Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced 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.
Features and Controls Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. • Do not overfill the tank. Do not fill the tank neck.
Features and Controls Fuel System WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane of 87. Refer to the specifications section beginning on page 178 for fuel tank capacity.
Fuel Valve The fuel valve is located on the left side of the ATV. It has three settings. Features and Controls Sportsman 90 Fuel Valve OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: The reserve setting allows Outlaw 90 Fuel Valve operation for approximately 7-10 miles (11-16 km). Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.
Features and Controls Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Lock the parking brake. 4. Fold out the kick-start lever on the left side of the ATV. NOTE: A 10/12mm wrench is provided in the tool kit for removing or installing the lever.
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. Perform the following procedures carefully.
Break-in Period 1. Fill the fuel tank with gasoline. See page 78. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 125. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 85. 6.
Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the ATV before each use to ensure it's in proper operating condition.
Pre-Ride Inspection Pre-Ride Checklist Item Remarks Tires Check condition and pressure Wheels / fasteners Inspect, ensure fastener tightness; check that axle nuts are secured by cotter pins Fuel and oil Check and fill as needed Throttle Check for proper operation Engine stop switch Check for proper function Page 159 161, 162 78, 80 25, 70, 71 68 Daytime running lights (if equipped) Check for proper operation 165 Brakelight 163 86 Check for proper operation
Pre-Ride Inspection Pre-Ride Checklist Item Remarks Page Air filter, pre-filter Inspect, clean or replace 156 Drive chain Check condition and slack; refer to drive chain adjustment 153 Frame nuts, bolts, fasteners Inspect, ensure tightness -- Loose or damaged components Visually inspect for any damaged components or loose fasteners -- Riding gear Wear helmet, goggles, protective clothing 92 87
Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating.
Starting the Engine 1. 2. 3. 4. Shift the transmission to neutral. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist. NOTE: The choke is fully on when the lever is pushed completely to the left. The choke is off when the lever is pushed completely to the right. The choke can be adjusted gradually, depending on how much choke is needed for starting. 5.
Starting the Engine 8. Squeeze the rear brake lever and press the starter button. NOTE: The rear brake lever must be engaged or the engine won't start. 9. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn't start, release the starter, wait five seconds, then activate for another five seconds. Repeat until the engine starts. 10. If the engine slows or stops, position the choke lever half way to allow proper engine warm up.
Stopping the Engine 1. Release the throttle completely and brake to a complete stop. 2. Shift the transmission to neutral. 3. Stop the engine. NOTE: There are three ways to stop the engine. • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. NOTE: To avoid draining the battery, always turn the key to the OFF position when the engine is not running. 4. Lock the parking brake. WARNING A rolling vehicle can cause property damage and serious injury.
Driving Safely Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Long Sleeves Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Riding Gear Driving Safely Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection.
Driving Safely Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Shift the transmission to neutral. 3. Start the engine and allow it to warm up. 4. Check your surroundings and determine your path of travel. 5. Squeeze the left brake lever. 6. Shift the transmission to the desired gear. 7. Slowly release the brake lever. 8. Slowly press the throttle with your right thumb and begin driving. 9. Drive slowly at first.
Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.
Driving Safely Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.
Driving on Slippery Surfaces Driving Safely Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
Driving Safely Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual.
Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
Driving Safely Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.
Driving Across Hillsides Driving Safely Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain direction.
Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner's manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it's necessary to turn around while climbing a hill is the K-turn: 1.
Turning Around on a Hill Driving Safely 5. Staying uphill of the ATV, turn the handlebars full left. 6. While holding the brake, release the 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. 7. Lock the parking brake and remount the 8 ft. (2.4 m) ATV from the uphill side, maintaining body weight uphill. 8. Restart the engine. 9. Squeeze the rear brake lever. 10. Shift the transmission to forward gear.
Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
Parking on a Hill or Incline Driving Safely Avoid parking on a hill or incline if possible. If it's unavoidable, follow these precautions: 1. Turn the engine off. 2. Lock the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illustration. 4. Turn the fuel valve off.
Driving Safely Driving Through Water Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths before driving through water. 2. If crossing a stream, choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4.
Driving Safely Driving Through Water Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in deeper water than recommended, it's critical to have it serviced as outlined in the maintenance chart beginning on page 114. The following areas need special attention: engine oil, gearcase oil, front and rear gearcases (if equipped) and all grease fittings. CAUTION Major engine damage can result from driving this ATV in deeper water than recommended.
Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
Driving Safely Driving in Reverse Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always look left, right and behind the ATV before backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
Driving Safely Hauling Cargo The Sportsman 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling cargo on the following pages. Never carry cargo on the Outlaw 90. WARNING Hauling cargo improperly can may cause loss of control and result in serious injury or death. Always carry cargo as instructed in safety decals and in the owner’s manual. • Place 1/3 of the cargo weight on the front rack and 2/3 on the rear rack.
Hauling Cargo Driving Safely • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section beginning on page 178. • Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or a tipover. Use suitable tie-downs or rope to secure the cargo. Do not allow cargo or tie straps to hang over the edges of the racks. • Carry only small loads that fit on the racks.
Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust 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 arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
Exhaust Emission Control System Emission Control Systems 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 optimal performance. Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.
Maintenance Periodic Maintenance Chart To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Record maintenance and service in the Maintenance Log beginning on page 198.
Periodic Maintenance Chart Maintenance Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
Maintenance Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often under severe use, such as in dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components.
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Q Steering -- Daily -- X Front suspension -- Daily -- X Rear suspension -- Daily -- Tires -- Daily -- Brake lever travel -- Daily -- X Remarks See Page Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist.
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) Drive chain -- Daily -- Inspect daily; adjust and lubricate if needed 153 CVT housing (if equipped) -- Weekly -- Drain water as needed, check often if operating in wet conditions 137 Perform break-in maintenance 83 XQ Break-in Maintenance Brake lever travel/brake freeplay 10 Monthly 100 (160) Inspect regularly 145 149 QE Spark plug 10 Monthly 10
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Remarks Miles (Km) See Page Battery 20 Monthly 200 (320) Check terminals; clean; test 166 X Engine oil change 30 6M 300 (480) Drain and change the oil 126 X Transmission oil 40 12 M 400 (640) Drain and change the oil 130 X Oil pre-filter screen 40 12 M 400 (640) Clean filter at every oil change; clean annually if ATV is operated less than 10 hours 127 X General lubricati
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks See Page Hours Calendar Miles (Km) 50 6M 500 (800) Check for proper sealing/air leaks -- E Carburetor air intake ducts/flange Q Drive belt 50 6M 500 (800) See your Polaris dealer -- XQ Brake pad wear 50 6M 500 (800) See your Polaris dealer -- QE Fuel system 100 12 M 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; replace lines every two year
Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Calendar Miles (Km) Remarks See Page X Wiring 100 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
Maintenance Lubrication Guide Item Engine Oil Lube Polaris Synthetic Youth Oil or Synthetic SAE 40 Gearcase (Transmission) Premium AGL Synthetic Oil Level Gearcase Lube Method See page 124. See page 130. Drive Chain Polaris Chain Lube or SAE 80/90 See page 153. X Front Suspension (A-Arm) Polaris All Season Premium Grease or grease conforming to NLGI No.
Lubrication Guide Maintenance Grease Points Grease Points 123
Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 182 for the part numbers of Polaris products.
Maintenance Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4. Remove the dipstick and check the oil level. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
Maintenance Engine Oil Change 1. 2. 3. 4. Position the vehicle on a level surface. Clean the area around the pre-filter plug. Start the engine. Allow it to idle for two to three minutes. Stop the engine. CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin.
Engine Oil Change Maintenance 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry. 8. Clean the pre-filter plug. Install a new sealing washer on the plug. NOTE: The sealing surfaces on the plug and crankcase should be clean and free of burrs, nicks or scratches. 9. Reassemble the pre-filter screen and spring to the pre-filter plug.
Maintenance Engine Oil Change 10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm). 11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. NOTE: See the specifications section beginning on page 178 for capacities. 12. 13. 14. 15. Reinstall the dipstick. Start the engine. Allow it to idle for one to two minutes. Stop the engine and inspect for leaks. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick. 16.
Fuel Filter Maintenance The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. Do not attempt to clean the fuel filter.
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 114. Polaris recommends the use of AGL Synthetic Gearcase Lubricant. See page 182 for the part numbers of Polaris products. 1. Position the vehicle on a level surface. 2. Remove the fill plug. 3.
Maintenance Transmission Oil Change 1. 2. 3. 4. 5. 6. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). Add the 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 Sportsman 90 11.8 oz.
Maintenance Spark Plugs Refer to the specifications section beginning on page 178 for spark plug and gap specifications. CAUTION 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.
Spark Plugs Maintenance Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body adjustments. Wet Fouled Plug The wet fouled insulator tip is black.
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 CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1.
Vehicle Immersion 5. Loosen the carburetor drain screw. 6. Turn the engine over several times using the electric start. 7. Dry the spark plug and reinstall it, or replace it with a new plug. 8. Tighten the carburetor drain screw. 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not.
Maintenance Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
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 bottom of the CVT cover. 1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug. 2. Shift the transmission to neutral. 3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and airdry the belt and clutches.
Maintenance Spark Arrestor To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. WARNING Failure to heed these warnings could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Wear eye protection and gloves. Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
Spark Arrestor 1. Remove the six bolts and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 3. Inspect the screen for wear and damage. Replace the arrestor if damage is found. 4. Reinstall the arrestor. 5. Torque the bolts to 7 ft. lbs. (9.5 Nm).
Maintenance Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
Carburetor Maintenance If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine. 2. Lock the parking brake. 3. Allow the engine to run for approximately five minutes. 4. Adjust the carburetor idle screw either in or out until the desired idle RPM is reached. Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclockwise) will lower RPM.
Maintenance Speed Control System Per ANSI / SVIA-1-2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed of youth models is restricted to under 10 MPH for the 50cc models and under 15 MPH for the 90cc models. The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer's request, remove or adjust any speed limiting devices. Your Polaris ATV has an adjustable throttle limiting screw.
Speed Control System Maintenance Throttle Stop Speed Control System Use the following procedure to control how far the throttle opens. 1. Loosen the jam nut. 2. Turn the screw inward to reduce speed or outward to increase speed. 3. Tighten the jam nut after adjusting.
Maintenance 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. Adjustment Nut 1/16" - 1/8" (1.5 - 3.
Maintenance Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. If the freeplay isn’t at specification, adjust the freeplay as outlined on the following pages. Measure Freeplay Brake Freeplay Specifications Model Front Brake Rear Brake 90cc Models .08”-.12" (2-3 mm) .08”-.
Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground. 4. While rotating the left front wheel, tighten the upper front brake adjuster 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.
Brake Freeplay Maintenance 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. 9. Verify that brake lever freeplay is at specification. See page 145. 10. Carefully lower the vehicle to the ground.
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 rotation, loosen the wing nut one full turn. 6. Verify that the left hand brake functions correctly. 7.
Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. When freeplay specifications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine when to service the brakes. Service the brakes when brake lever travel reaches the total lever travel measurement listed in the Measure table below.
Maintenance Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. 1. Set the handlebars in a straight-ahead position.
Maintenance Toe Alignment 3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle. 4. Measure the distance from the string to the rim at the front and rear of the front rim. Rear measurement should be 1/16" - 1/8" (2-3 mm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service.
Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension. Rotate the adjuster either clockwise or counter-clockwise to make adjustments.
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 114. Lubricate more often under severe use, such as in dirty or wet conditions. See page 182 for the part numbers of Polaris products. CAUTION Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure.
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.
Maintenance Drive Chain Slack Adjustment CAUTION Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud. 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. Turn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). 5. Tighten the four rear housing mount bolts to 43 ft. lbs. (60 Nm).
Maintenance Air Filter 1. Remove the seat. See page 21. 2. Release the air box cover spring clips and remove the cover. 3. Remove the foam air filter. Wash the foam filter in warm soapy water, then rinse and let dry. If the filter is damaged, install a new foam filter. 4. Apply a commercially available foam filter lubricant to the foam filter.
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. CAUTION Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear and severe damage to the engine.
Maintenance Handlebar Adjustment WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference. 1. Remove the pod to access the handlebar bolts. Loosen the four bolts. 2.
Maintenance Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8" (3 mm) or less.
Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 1/8" (3 mm) Wheel Removal 1. Stop the engine and lock the parking brake. 2. Loosen the wheel bolts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel bolts and remove the wheel.
Wheel Installation Maintenance 1. Lock the parking brake. 2. 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. 3. Install the wheel bolts and finger tighten them. 4. Lower the vehicle to the ground. 5. Securely tighten the bolts to 22 ft. lbs. (30 Nm).
Maintenance Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized Polaris dealer. Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.
Tail Light Lamp Replacement If the brakelight doesn't work, the lamp may need to be replaced. 1. Remove the two screws securing the lens cover. Remove the lens cover. 2. Remove the lamp and replace it with a new recommended lamp. 3. Test the light for proper operation. 4. Reinstall the lens cover.
Maintenance Indicator Light Lamp Replacement 1. 2. 3. 4. 5. 6. 164 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.
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. Remove the front cab (Outlaw only). 2. Disconnect the lights from the harness. 3. Remove the rubber cover from the back of the light assembly. 4. Press the lamp retainer inward and turn it counter-clockwise to remove it.
Maintenance Battery The battery in your Polaris ATV is a sealed battery. The sealing strip cannot be removed. Never add water to this type of battery. Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Battery Maintenance Battery Removal 1. 2. 3. 4. Disconnect the hold-down straps securing the electrical box and battery in position. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable next. Lift the battery out of the ATV.
Maintenance Battery Battery Installation and Connections 1. 2. 3. 4. 5. Set the battery in its holder. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Attach the hold-down strap. Verify that cables are properly routed. NOTE: When installing a new battery, make sure it's fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life.
Maintenance Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
Maintenance Cleaning Washing the ATV The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots. Washing Tips • • • • Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle.
Cleaning Maintenance 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 NOTE: If warning and safety labels are damaged, contact your Polaris dealer for free replacement. Grease all zerk fittings immediately after washing.
Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • 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.
Storage Maintenance Exterior Make necessary repairs and clean the vehicle as recommended. See page 169. Battery Storage Remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
Maintenance Storage Stabilize the Fuel Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period. 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount.
Storage Maintenance Engine Oil Change the oil. See page 126. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 114.
Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 114. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground. 3. Be sure the storage area is well ventilated. 4. Cover the vehicle with an appropriate cover. NOTE: Do not use plastic or coated materials.
Transporting the ATV Maintenance Follow these procedures when transporting the ATV. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap and seat. 5. Turn the fuel valve off. 6. 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 the unit.
Specifications Outlaw 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 178 1 Rider/170 lbs. (77 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 1.7 gallons (6.4 liters) .23 gallons (.86 liters) Electric with kick-start backup Automatic CVT Chain Single A-arm with 5" (12.7 cm) of travel Swing arm with 6" (15.
Specifications Outlaw 90 Front/Rear Brakes Parking Brake Front Tires Rear Tires Dry Weight Length/Width/Height Wheel Base Ground Clearance Brake Light Daytime Running Lights Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 270 lbs. (122.4 kg) 61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm) 41.5" (105 cm) 4" (10 cm) at swing arm, 7.7" (19.
Specifications Sportsman 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 180 1 Rider/170 lbs. (77 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 2 gallons (7.7 liters) .22 gallons (.85 liters) Electric with kick-start backup Automatic CVT Chain Single A-arm with 5" (12.7 cm) of travel Swing arm with 6" (15.
Specifications Sportsman 90 Front Rack Capacity Rear Rack Capacity Front/Rear Brakes Parking Brake Front Tires Rear Tires Dry Weight Length/Width/Height Wheel Base Ground Clearance Brake Light Daytime Running Lights 15 lbs. (6.8 kg) 30 lbs. (13.6 kg) Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 289 lbs. (131 kg) 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm) 41.5" (105 cm) 4" (10 cm) at swing arm, 7.7" (19.
Polaris Products Part Number 2876248 2876249 2872175 2872176 2870791 2873602 2872348 182 Description Engine Lubricant Synthetic Youth Oil (qt/.95 l) Synthetic Youth Oil (gal/3.8 l) Semi-Synthetic 20W-40 Oil (qt/.95 l) Semi-Synthetic 20W-40 Oil (gal/3.8 l) Fogging Oil, Aerosol Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt/.
Polaris Products Part Number 2871322 2871423 2871326 Description Grease All Season Premium Grease (3 oz./89 ml) All Season Premium Grease (14 oz.
Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts.
Troubleshooting Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery with .
Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer 186
Engine Runs Irregularly, Stalls or Misfires Possible Cause Troubleshooting 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 .
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clean and/or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer 18
Troubleshooting Engine Stops or Loses Power 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
Warranty LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
Warranty EXPORTED VEHICLES How to Get Service If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage.
Warranty U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
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.
Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 100 Hours 120 Hours 150 Hours 199
Maintenance Log DATE 200 SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS
Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 201
Index A Accessories. . . . . . . . . . . . . . . . . . 177 Age Warning . . . . . . . . . . . . . . . . . 36 Air Filter . . . . . . . . . . . . . . . . 156-157 Axle and Wheel Nuts . . . . . . . . . . 162 B Battery Installation/Connections . . . 168 Removal . . . . . . . . . . . . . . . 167 Storage. . . . . . . . . . . . . 168, 173 Boots. . . . . . . . . . . . . . . . . . . . . . . . 93 Brake Adjustment, Front . . . 146-147 Brake Adjustment, Rear . . . . . . . . 148 Brake Freeplay . . . . . . . . . . .
Index I-J N Indicator Light . . . . . . . . . . . . . . 164 Indicator Lights. . . . . . . . . . . . . . . 77 No Passenger Warning. . . . . . . . . . 39 K Oil. . . . . . . . . . . . . . . . . . . . . . . . . 124 Oil Change, Engine . . . . . . . 126-128 Oil Change, Transmission . . . . . . 131 Oil Check, Engine . . . . . . . . . . . . 125 Oil Check, Transmission . . . . . . . 130 Oil, Engine . . . . . . . . . . . . . . . . . . 124 Operation Warning. . . . . . . . . . . . . 35 Key Switch . . . . . . . .
Index S Switches Engine Start Button . . . . . . . . 69 Engine Stop Switch . . . . . 19, 68 Horn Button. . . . . . . . . . . . . . 19 Ignition Switch . . . . . . . . . . . 23 Main Key Switch. . . . . . . . . . 67 Tether Switch . . . . . . . . . . . . 23 204 T Tail Light . . . . . . . . . . . . . . . . . . . 163 Tether Strap . . . . . . . . . . . . . . . . . . 23 Throttle . . . . . . . . . . . . . . . . . . . . . 70 Throttle Cable Adjustment . . . . . 144 Throttle Control . . . . . . . . . . . . . . .
