Polaris 9921796 - Manuals

6 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 words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potentia...

8 Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongl...

9 Safety Safety Training If you purchased a used Polaris ATV, you can take the ATV RiderCourse sm by calling ATV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchas- ers of a used Polaris ATV will be charged for this training. FOR MORE INFORMATION ABOUT ATV SAFETY, call th...

10 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 exc...

11 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings su...

12 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 veh...

13 Safety Safety Warnings 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. Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your...

14 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...

15 Safety 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 caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventila...

16 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 inspecti...

17 Safety Safety Warnings Carrying a Passenger Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV. Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could...

18 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 de...

19 Safety Safety Warnings Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience. Physical Control of the ATV Remov...

20 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 ...

21 Safety Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 84. Operating on Steep Hills Operating on excessively steep hills could cause an overturn. ...

22 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 p...

23 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 t...

24 Safety Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.Always maintain a steady speed when climbing a hill.If all forward speed is lostIf you lose all forward speed: Keep your weight uphill. Apply t...

25 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 ...

26 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 slowly and use extra c...

27 Safety 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...

28 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 footr...

29 Safety 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...

30 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 ...

31 Safety Safety Warnings 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 thr...

32 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 ...

33 Safety Safety Labels and Locations Operation Warning WARNINGImproper 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 instru...

34 Safety Safety Labels and Locations Discretionary Warning WARNINGNever 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 di...

36 Safety Safety Labels and Locations No Passenger Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 + +

37 Safety 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 lbs. (7 kg)Rear 30 lbs. (14 kg) 7174556 + +

38 Safety Safety Labels and Locations Clutch Cover Warning WARNINGNO 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 ...

40 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 126.These units are not designed for adult use. Se...

41 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. 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 agai...

42 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 68. 5. Shift Lever - The shift lever is on the ri...

43 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...

44 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...

45 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....

46 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.

47 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 ...

48 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...

50 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...

51 Riding Rules X 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...

53 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 tra...

54 Respect your ATV; respect your environment; and you will earn the respect of everyone. Enjoy riding your new Polaris ATV!

56 Vehicle Identification Numbers Record your ATV's identification num- bers and key number in the spaces pro- vided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your exist...

57 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. Key Key OUTLAW SPORTSMA...

58 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 ...

59 Features and Controls Horn Button Use the horn for emergencies and to let others know you’re near. Engine Start Button The start button is located slightly above the choke lever.1. Attach the tether strap securely to the vehicle and to the rider's right wrist.2. Shift the transmission to neutral....

60 Features and Controls Throttle Controls 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 thr...

61 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 froze...

62 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. ...

63 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....

64 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. Release the brake lever.4. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. 5. A...

65 Features and Controls Lights 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 ...

66 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane of 87. Refer to the specifications sec- tion beginning on page 162 for fuel tank capacity. Gas Cap

67 Features and Controls Fuel Valve The fuel valve is located on the left side of the ATV. It has three settings. OFF: For vehicle storage and when transporting.ON: For normal operation.RES: For reserve supply if main supply is exhausted. The reserve setting allows operation for approximately 7-10 m...

68 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-sta...

69 Operation 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 outlined in the safety section of this owner’s manual. Break-in Period The break-in period for your ...

70 Operation Break-in Period 1. Fill 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 are...

71 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. 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-i...

72 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 / lev...

74 Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 8. 2. Do not allow anyone under 12 years of age to operate this vehicle. 3. Never carry a passenger on this ATV.4. Engine exhaust fumes are poisonous. Never start the engine or l...

76 Operation Starting the Engine NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Shift the transmission to neutral.2. Lock the parking brake.3. Turn the fuel valve on.4. Sit on the vehicle. Attach th...

77 Operation Starting the Engine 7. Turn the ignition key to ON.8. Squeeze 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, re...

78 Operation Stopping the Engine 1. Release the throttle completely.2. Apply the brakes until the vehicle stops moving.3. Shift the 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 t...

79 Operation 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 ...

80 Operation 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, s...

81 Operation Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles.6. Never open the throttle suddenl...

82 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 on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas.

83 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 forw...

84 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 t...

85 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 dro...

86 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...

87 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 cont...

88 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. Shift the transmission to neutral.3. Shut off the engine.4. Dismount on the...

89 Operation Turning Around on a Hill 7. Lock the parking brake and remount the ATV 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 wit...

90 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.

91 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 u...

92 Operation 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 precautions when operating through water:1. Determine water depth and current before entering water. 2. If crossing a st...

93 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 n...

94 Operation 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. Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may caus...

96 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 require- ments. Operation on Public Lands in the U.S.A. Your Polaris vehic...

97 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be main- tained at Polaris specifications to achieve optimal performanc...

98 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. ...

99 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 serv...

100 Maintenance Periodic Maintenance Chart Improperly performing the procedures marked with a Q 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. Maintenance Chart Key X Perform these...

106 Maintenance Lubrication Guide X Perform these procedures more often for vehicles subjected to severe use Item Lube Method Engine Oil Polaris Synthetic Youth Oil or Synthetic SAE 40 See page 108. Gearcase (Transmission) Oil Level Premium AGL Synthetic Gearcase Lube See page 114. Drive Chain Polar...

107 Maintenance Lubrication Guide Grease Points Grease Points

108 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. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 166 for the part numbers ...

109 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. Tip: ...

110 Maintenance Engine Oil Change 1. Position the vehicle on a level surface.2. Clean the area around the pre-filter plug.3. Start the engine. Allow it to idle for two to three minutes.4. Stop the engine. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

111 Maintenance Engine Oil Change 5. Place a drain pan under the engine crankcase.6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry. 8. Clean the pre-filter plug. Install a new sealing washer...

112 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. See the specifications section beginning on page 162 for capacities. 12. Reinstall the dipstick.13. Start the...

113 Maintenance Fuel Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. Do not attempt to clean the fuel filter.

114 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...

115 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. Add the recommended...

116 Maintenance Spark Plugs 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 opera...

117 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 t...

118 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, restarti...

119 Maintenance 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...

120 Maintenance Constant Variable Transmission (CVT) System 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 bee...

121 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. Remove the drain plug. Allow the water to drain. Reinstall the dr...

122 Maintenance Spark Arrestor To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. Failure to heed these warnings could result in serious injury or death.• Do not perform service on the spark arrestor while the s...

123 Maintenance Spark Arrestor 1. Remove the six bolts and remove the arres- tor 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 com- pressed air. 3. Inspect the ...

124 Maintenance Carburetor 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 ...

126 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...

127 Maintenance 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 Screw

128 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 acc...

129 Maintenance 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. Brake Freeplay Specificati...

130 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 w...

131 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 f...

132 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, ti...

133 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 wh...

134 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 align...

136 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 sprin...

137 Maintenance Drive Chain Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the gen- eral lubrication interval specified in the Periodic Maintenance Chart beginning on page 98. Lubricate more often under severe use, such as in dirty or wet conditions. See page 16...

138 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. Tight...

139 Maintenance Drive Chain Slack Adjustment 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). Hold the adjuster stud securel...

140 Maintenance Air Filter 1. 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 avai...

142 Maintenance Handlebar Adjustment 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 procedu...

143 Maintenance Tires 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 manua...

144 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 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...

145 Maintenance Wheel Installation 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 vehicl...

146 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.

147 Maintenance 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...

148 Maintenance Indicator Light Lamp Replacement 1. Remove the handlebar cover or pod to access the lamps.2. Remove the indicator wire connections from the harness.3. Remove the nut from the back side of the indicator lamp.4. Remove the lamp.5. Apply dielectric grease to the socket and install the n...

149 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 fr...

150 Maintenance Battery 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. Th...

151 Maintenance Battery Battery Removal 1. Disconnect the hold-down straps securing the electrical box and battery in position.2. Disconnect the black (negative) battery cable first.3. Disconnect the red (positive) battery cable next.4. Lift the battery out of the ATV.

152 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 charg...

153 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...

154 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 surfac...

156 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 vehi- cle....

157 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 recha...

158 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 Po...

160 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 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle sligh...

161 Maintenance Transporting the ATV 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 secure...

162 Specifications Outlaw 90 Rider Capacity/Maximum Weight 1 Rider/180 lbs. (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 wi...

166 Polaris Products Part Number Description Engine Lubricant 2876248 Synthetic Youth Oil (qt/.95 l) 2876249 Synthetic Youth Oil (gal/3.8 l) 2872175 Semi-Synthetic 20W-40 Oil (qt/.95 l) 2872176 Semi-Synthetic 20W-40 Oil (gal/3.8 l) 2870791 Fogging Oil, Aerosol Gearcase / Transmission Lubricants 2873...

167 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease (3 oz./89 ml) 2871423 All Season Premium Grease (14 oz./414 ml) Miscellaneous Additives 2871326 Carbon Clean Plus

168 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 fu...

169 Troubleshooting Engine Doesn’t Turn Over Engine Pings or Knocks 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 Possible Cause Solution Poor q...

170 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 you...

171 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 ...

172 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 Poss...

173 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 s...

174 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 f...

175 Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This ...

177 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 F...

178 Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for expo...

179 Warranty EXPORTED VEHICLES How to Get Service I f 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 requi...

182 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...

186 Index A Accessories . . . . . . . . . . . . . . . 161 Age Restrictions . . . . . . . . . . . . . 13 Air Filter . . . . . . . . . . . . . . 140 - 141 Axle and Wheel Nuts . . . . . . . . . 146 B Battery . . . . . . . . . . . . . . . 150 - 153 Installation and Connections 152 Removal . . . . . . . ...