Polaris Scrambler 50 - Manuals

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS 37 ...

6 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are ess...

7 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Know Your Vehicle As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read...

8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your ATV or in this manual, alerts ...

9 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or ...

11 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to...

12 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDBeginning...

13 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.HOW TO AVOID THE HAZARDNever carry a passenger...

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss ...

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.Operating without eye pro...

17 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.Consuming alcohol and/or drugs b...

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

21 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

25 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

26 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the single leve...

27 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

32 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by ...

33 SAFETY Safety Decals and Locations See your Owner’s Manual Supplement for specifications. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. T IRE PRESSURE (PSI): FRONT ___ REAR ___ M AXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE...

34 SAFETY Safety Decals and Locations ATTENTION D Operation of this vehicle without the filter element will severely damage the engine. D Clean air filter often, more frequent cleaning required in dusty conditions Under Seat Moving parts hazard under belt-clutch guard. To prevent serious injury, do ...

35 SAFETY Safety Decals and Locations ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY: POLARIS IND DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS ...

36 SAFETY Safe 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. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...

37 CONTROLS Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. WARNING Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped wit...

38 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduc...

39 CONTROLS Light Switches The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI-LO beams. NOTE: The lights won’t work unless the key is in the “on” position and the shut-off switch is in the “...

40 CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.Always test brake lever travel and master cylinder fluid level before ridin...

41 CONTROLS Parking Brake Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever. I...

42 CONTROLS Auxiliary Brake The auxiliary brake (1), is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels slide while using the auxiliary brake, r...

43 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 59 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, either below the fender or on the side panel. It has thr...

44 CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the ...

45 CONTROLS Oil Injection Tank - 2-Cycle Models Models with 2-cycle engines have oil injection. The oil injection tank filler cap (1) is located on the front of the vehicle. Tank capacity is two quarts (1.9 l.). Mixing brands or using a non-recommended oil may cause serious engine damage. We recomme...

46 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear N: Neutral L: Low Gear R: Reverse P: Park Whenever the ATV is left unattended, always place the transmission in g...

47 CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped with automatic decompressors. This ...

48 FEATURES All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is ...

49 FEATURES All Wheel Drive (AWD) System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort ...

50 FEATURES Indicator Lights The configuration of the indicator lights differs with individual models. Not every model is equipped with all of the lights, and the lights on some models appear in the speedometer. The information in your owner’s manual supplement and on this page will help you identif...

51 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to appro...

52 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster.1. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in:H = High RangeL = Low RangeN = NeutralR = ReverseP = ParkE or ...

53 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button on the left handlebar is also the mode button . NOTE: If using th...

54 FEATURES Instrument Cluster Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off. ...

55 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift th...

56 OPERATION Break-In Period 2-Cycle Engines The break-in period for your new Polaris ATV is defined as the time it takes to use the first tank of fuel. 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 m...

58 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel and oil tanks - Fill both tanks to their proper levels.3. All brakes - Check operation, ...

59 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle.4. Pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pulled completely out. Th...

60 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank ...

61 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the weights specified in your owner’s manual supplement.Cargo weight should be evenly distributed (...

63 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...

64 OPERATION Driving Safely Making Turns Some Polaris ATVs are equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip tra...

65 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick...

66 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ 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...

67 OPERATION Driving Safely Sidehilling 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 toward th...

68 OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the brakes slightly to aid in slowing, using the single brake lever. NOTE: Familiarize yourself with...

69 OPERATION Driving Safely Turning Around on a Hill 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. Stop and lock the parking brake while keeping body weight uphill.2. L...

70 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ...

71 OPERATION 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

72 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...

73 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.1. Place the transmission in gear.2. Set the parking brake.3. Always block the rear wheels on the downhill side. See illustration. 4. Shut o...

74 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or eleme...

75 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information.Polaris has a wide range of additional accessories available ...

76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Item Hours/ Miles Frequency Remarks Brake Syst...

80 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, ...

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations (7) (9) (8) (6) 4 O’clock position (6) (11) (10) (12) (14) (15) (13) (13)

84 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs.20 hrs.50 hrs. 100 hrs.

85 MAINTENANCE AND LUBRICATION Lubrication Recommendations Polaris 2-Cycle Lubricants Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. Our ongoing lab and field tests have resulted in a new generation of 2-cycle lubrican...

86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lub...

87 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 1. Position the vehicle on a level surface.2. Clean the area around the drain plug, which is located on either the bottom of the oil tank or on the bottom of the engine. 3. Run the...

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 11. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on t...

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4, Magnum 330 4x4, Trail Boss 12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place the gear selector in neutral and set the parking brake.14. Start t...

91 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be c...

92 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 1. If equipped, remove the propshaft shield from the right side of the vehicle to access the fill plug. 2. Remove the fill plug.3. Remove the t...

93 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check - Models with Dipstick On most 2x4 models, the transmission dipstick (1) is located on the right side of the machine. On the Sportsman, the dipstick is located near the rear brake disc.The transmission lubricant level ...

94 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - 2x4 Models 7. Tighten the jam nut securely while holding the adjuster bolt.8. Add the proper lubricant through the dipstick hole until the oil level is between the upper and lower limits. Do not overfill. 9. Check f...

95 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gea...

96 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8 ″ below the top of the f...

97 MAINTENANCE AND LUBRICATION Lubrication Recommendations Counter Balance Oil Check - 400 2-Cycle Engines The counter balance oil should be checked semi-annually and oil should be added or changed as needed. The oil should be changed annually and before off season storage. If the machine is used in...

98 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank is located either on the left side of the vehicle (external tank models)(1) or on the engine (2).1. Position the machine on a level surface.2. Start the engine and let it idle for 20-30 seconds. Stop the engine....

99 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle on Gen IV machines, remove the left side panel. See page 111.The fluid level must be maintained between the minimum and maximum marks o...

100 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if nec...

101 MAINTENANCE AND LUBRICATION Engine Cooling System NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/4...

102 MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 250 Engines 1. Before adjusting the oil pump, check the engine idle RPM and carburetor settings in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn the adjuster (1) in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 cm) o...

103 MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments in your owner’s manual supplement. 2. Loosen the throttle cable jam nut and turn the adjuster in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 cm) t...

104 MAINTENANCE AND LUBRICATION Adjustments Front Brake The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more ...

105 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when worn to 3/64 ″ (.1 cm), which is about the thickness of a U...

106 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether...

107 MAINTENANCE AND LUBRICATION Adjustments Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non...

108 MAINTENANCE AND LUBRICATION Adjustments Handlebars The handlebars can be adjusted for rider preference.1. Locate handlebar bolts (1). On models with a headlight pod, remove the upper headlight pod. On other models, remove the handlebar cover. 2. Loosen the four bolts.3. Adjust the handlebar to t...

109 MAINTENANCE AND LUBRICATION Adjustments 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 mixt...

111 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal - Gen IV NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, p...

112 MAINTENANCE AND LUBRICATION Adjustments Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the ...

113 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel nuts and fing...

114 MAINTENANCE AND LUBRICATION Adjustments Front 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. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (...

115 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.Always inspect the drive chain prior to operating the vehicle. Check for damaged or mis...

116 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack - Concentric Drive Models Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three posit...

118 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service - 2-Cycle Engines 1. Remove the ATV seat.2. Release the clips securing the cover assembly to the air box.3. Loosen the clamp securing the filter, and remove the filter.4. Remove the foam pre-filter from the main filter.5. ...

119 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service - 4-Cycle 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rins...

120 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Headlight Lamp Replacement - Scrambler 1. Remove the wire harness connector from the back of t...

121 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Trail Blazer 1. Remove the front cover and unplug the light harness.2. Remove the rubber cap from the back of the headlight to reveal the retention screw. 3. Remove the small phillips head screw, and carefully remove the bulb from t...

122 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Gen IV 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. 3. Lift the pod slightly while depressing the...

123 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment - Gen IV The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from...

124 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement - Gen IV 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the ...

125 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and repla...

126 MAINTENANCE AND LUBRICATION Spark Plugs Refer to your owner’s manual supplement for recommended spark plug and gap specifications. 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 be...

127 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Check the airbox for any water and dry it if water is present. 3. ...

128 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow compone...

130 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV.Water will enter the recoil housing if the starter handle is disengaged from the rope guid...

131 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pi...

132 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine a...

133 MAINTENANCE AND LUBRICATION Battery (Conventional) 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 wit...

134 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1).To refill use only distilled water. Tap wate...

135 MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in the battery holder.2. With conventional batteries, install the battery vent tube. Sealed batteries do not have a vent tube. NOTE: The vent tube must be free of obstructions and securely installed. If not, battery gase...

136 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge t...

137 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 141 for the part numbers of Polaris-recommended products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned ...

138 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 141 for the part numbers of Polaris-recommended products. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or h...

139 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 141 for the part numbers of Polaris-recommended products. Fog the Engine 2 Cycle - Use Polaris Fogging Oil and follow the directions on the can. 4-Cycle - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0...

140 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Conventional Battery: Remove the battery and add distilled water to the proper level. Do not use tap water , which may contain minerals that reduce battery life. Apply Polaris di-electric grease to the terminal bolts a...

141 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602...

142 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low ra...

143 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

144 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...

145 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn 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...

146 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain ...

148 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states ...

149 INDEX A Accessories 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 102-117 . . . . . . . . . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter 118-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . All...

Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers. Part No. 9917492 Rev. 05 PRINTED IN THE US...

6 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. The safety alert symbol , on your vehicle or in this manual, alerts you to ...

7 Safety The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. CAUTION NOTE: A note will alert you to important information or instructions.

9 Safety S Read this manual and all labels carefully and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course. Riders should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800...

10 Safety S Never operate an ATV without wearing an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt or jacket, and long pants. S Never consume alcohol or drugs before or while operating this ATV. S Never operate at e...

11 Safety S Always follow proper procedures for turning as described in this manual. Practice turn- ing at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident. S Ne...

12 Safety S Always follow proper procedures for crossing the side of a hill as described in this manu- al. 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 te...

13 Safety S Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg. 114), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward mo- tion, do not make sudden turns or stops,...

14 Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the veh...

15 Table of Contents Welcome 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Table of Contents 15 . . . . . . . . . . . . . ....

16 Table of Contents ADULT SECTION (continued) Driving Safely 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hauling Cargo 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise Emission Control System Regulation 120 ....

18 Know Your ATV PARENTS: Polaris Youth ATVs are equipped with an electronic 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 on page 141.These units are not designed for adult use. ...

19 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....

20 Know Your ATV 3. 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 93. 3

21 Know Your ATV 4. 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. 5. Seat Latch - To remove the seat, reach under the rear of the cab and pull back on the seat latch. To replace the seat, set it in plac...

22 Know Your ATV 6. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left hand lever (A) controls the rear brake. The right hand lever (B) controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brakes at the same...

23 Know Your ATV 7. 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. If you have a Scrambler, the ignition switch key is on the right side of the ATV (A). If you have a Sportsman, it’s on the pod (B). A B

24 Know Your ATV 8. 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. If you have a Sportsman, the switch is on the p...

25 Know Your ATV Let’s review the three ways to stop your ATV: 1. Push the stop switch down.2. Pull off the tether strap.3. Turn the key off.

26 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...

27 Pre-Ride Check 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 f...

29 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.The adult with you is yo...

32 Riding Rules " Never ride alone. An adult should always be watching you in case you need help. Al- ways drive within the sight of an adult. " Never ride on public trails. " Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars,...

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

36 Safety Decals Warning and safety decals have been placed on the ATV for the protection of the operator. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed on t...

37 Safety Decals Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear; Never use on public roadsNever carry passengers; Never use with drugs or alcohol NEVER operate: without proper training or instruction; at speeds too fast for your skills or the...

39 Safety Decals Scrambler 50 Age Warning Decal S Kids under age 6 should NEVER operate this ATV. Kids under 6 have an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owner’s Manual and labels. S Make sur...

41 Safety Decals Scrambler 90/Sportsman 90 Age Warning Decal S 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. S Adult supervision is required. S Make sure operators follow Owner’s Manual and lab...

45 Safety Decals ATTENTION S Operation of this vehicle without the filter element will severely damage the engine. S Clean air filter often, more frequent clean- ing required in dusty conditions. 5 S Specific carburetor jetting and adjustments are required depending on temperature and altitude. See ...

47 Safety Decals 7 Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death. DO NOT TOW F...

49 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, so be sure to explain to your young driver that the following hazards MUST be avoided at all times.

52 Driver Warnings POTENTIAL HAZARDCarrying a passenger on this ATV.WHAT CAN HAPPENGreatly reduces your ability to balance and control this ATV.Could cause an accident, resulting in harm to you and/or your passenger.HOW TO AVOID THE HAZARDNever carry a passenger. The long seat is to allow the operat...

53 Driver Warnings POTENTIAL HAZARDOperating this ATV on paved surfaces, including sidewalks, paths, parking lots and driveways.WHAT CAN HAPPENThe 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 cont...

55 Driver Warnings POTENTIAL HAZARD: Operating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPEN: Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.Operating without eye protectio...

59 Driver Warnings POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV each time you use it to make sure the ATV is in safe operatin...

60 Driver Warnings POTENTIAL HAZARDRemoving hands from handlebars or feet from footrests during operation.WHAT CAN HAPPENRemoving even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, you...

62 Driver Warnings WARNING POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtu...

64 Driver Warnings POTENTIAL HAZARD: Climbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the Owner’s Manual beginning on page 106.Always check the terrain car...

65 Driver Warnings Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Go straight down the hill when possible. WARNING POTENT...

66 Driver Warnings POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever try to turn the ATV around on any hill until you’ve mastered the turning technique (on level g...

67 Driver Warnings If you begin rolling backwards: Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the front brake slowly. When fully stopped, apply rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side...

68 Driver Warnings WARNING POTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENSkidding or sliding can cause loss of control.If the tires regain traction unexpectedly, the ATV could overturn.HOW TO AVOID THE HAZARDOn slippery surfaces such as ice, travel slowly and use extra caution to reduce the cha...

76 Vehicle Identification Numbers The frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. In the event your vehicle is stolen, these numbers are ...

79 Controls Main Switch The main switch is located on the right-hand side of the Scrambler (A) and on the pod of the Sportsman (B). This switch is operated with a key and must be turned clockwise to the ON position before starting the engine. Leaving the keys in the ignition can lead to unauthorized...

80 Controls Engine Stop Switch The stop switch (C) is located on the top of the left handlebar. 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 emergenc...

82 Controls Throttle Controls 4 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 probl...

83 Controls Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (A). The throttle lever is spring loaded. 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...

84 Controls Brakes To activate the rear brake (A), squeeze the left-hand lever toward the handlebar. The front brakes (B) are activated by squeezing the lever on the right-hand handlebar. Applying only one brake could cause loss of control and result in serious injury or death. Always apply both bra...

85 Controls Brakes Setting the Parking Brake 1. Squeeze the left-hand brake lever (A).2. Push the park brake lock (B) down. This will prevent the lever from returning to the released position. 3. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release a...

86 Controls Brakes Parking Brake NOTE: This vehicle has a PVT system that’s always in forward. Always lock the park brake before starting the engine.Always lock the parking brake whenever the vehicle is left unattended.Since the transmission is always in forward gear, activating the throttle to warm...

87 Controls Lights Indicator Lights Each Polaris ATV has different indicator lights. Your model has a low oil warning light. When the red dot is illuminated, it means the oil level is getting too low. Polaris Youth ATVs are not equipped with lights. The ATVs are designed for off-road use only and mu...

88 Controls Fuel System Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the ...

89 Controls Fuel System Gas Cap The fuel tank filler cap (A) is located directly below the handlebars. The tank has a capacity of 1.3 gallons (5 liters). Use unleaded gasoline with a minimum pump octane of 87. A The engine exhaust from this product contains chemicals known to cause cancer, birth def...

90 Controls Fuel System Fuel Valve The fuel valve (A) is located on the right-hand side of the ATV. It has three positions:OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 7-10 mile (11-16 km) range o...

91 Controls Oil System The oil tank (A) is located under the seat and has a capacity of 1.1 quarts (1 liter). Always top off the oil level when refueling. NOTE: See page 21 for seat removal instructions. CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recomme...

94 Break-in Period The break in period for your new Polaris ATV is the length of time it takes to use the first tank of gas. 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 an...

96 Daily Pre-Ride Inspection Use the following checklist to make sure the ATV is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel and oil tanks - Fill both tanks to their proper levels.3. All brakes - Check operation and adjustme...

97 Daily Pre-Ride Inspection 6. Engine stop switch - Check for proper function.7. Wheels - Check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins. 8. Drive chain - Condition and slack; refer to drive chain adjustment.9. Air cleaner element - Check for dirt; ...

98 Starting the Engine 1. Set the parking brake and turn the fuel tank valve to ON.2. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist. Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never ru...

100 Driving Safely Safe 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. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe h...

102 Driving Safely Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up.3. Check your surroundings and determine your path of travel. 4. Release the parking brake.5. Slowly depress the throttle with your right ...

103 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 ...

104 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 surfac...

106 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...

107 Driving Safely 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 t...

108 Driving Safely Driving Across Hillsides 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. WARNING

109 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...

110 Driving Safely Turning Around on a Hill 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. Stop and lock the parking brake while maintaining body weight uphill.2. Shut o...

111 Driving Safely 4. Staying uphill of the ATV, turn the handlebars full left.5. 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. 6. Lock the parking brake an...

112 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. Excessive speed can cause lo...

113 Driving Safely Parking on a Hill or Incline Avoid parking on a hill or incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.2. Set the parking brake.3. Always block the rear wheels on the downhill side as shown in the illustration. 4. Shut off the fuel supply...

114 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 (A). Follow these procedures when operating through water:1. Determine water depths before driving through water. 2. If crossing...

115 Driving Safely 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 127. The following areas need special attention: engine oil, gearcase oil,...

116 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles...

117 Hauling Cargo The Sportsman 90 was designed to carry a certain amount of load. Never exceed the weight capacities listed in the specifications section of the owner’s manual. Never carry cargo on a Scrambler.Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack...

118 Hauling Cargo S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads ...

120 Noise Emission Control System Regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or elem...

121 Maintenance PVT System The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this system re...

123 Maintenance Battery The battery in your Polaris ATV is a sealed lead acid type battery. The sealing strip cannot be removed. Water must not be added to this type of battery. Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff ...

124 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.

125 Maintenance Battery Battery Installation and Connections 1. Set the battery in its holder.2. Connect and tighten the red (positive) cable first.3. Connect and tighten the black (negative) cable last.4. Attach the hold-down strap.5. Verify that cables are properly routed. NOTE: When installing a ...

126 Maintenance Periodic Maintenance Schedule To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are: S Spark plug wrench S Screwdriver S Tire pressure gauge Maintenance intervals are based upon average riding conditio...

127 Maintenance Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Maintenance Chart Key " Perform these operations more oft...

128 Maintenance Periodic Maintenance Schedule Item to Inspect Hours/ Miles Frequency Remarks Brake System Pre-ride Pre-ride Inspect Tires Pre-ride Pre-ride Inspect Wheels Pre-ride Pre-ride Inspect Frame nuts, bolts, fasteners Pre-ride Pre-ride Inspect; tighten any loose hardware Throttle Pre-ride Pr...

132 Maintenance Lubrication Recommendations Item Lube Method Frequency 1. Engine Oil Polaris 2-cycle oil Fill oil tank. As needed and when refueling 2. Gearcase Oil Level Polaris Premium Synthetic gearcase lube See Page 151. Change annually or at 100 hrs. Maintain in safe range. 3. Drive Chain O-Rin...

134 Maintenance Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 hrs. 25 hrs.50 hrs.75 hrs. 100 hrs.

136 Maintenance Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster (A) in the direction required to increase or decrease spring tension. Handlebar Adjustment A Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts c...

138 Maintenance Axle and Wheel Nut Torque Specifications Check the following nuts occasionally and when they’ve been loosened for maintenance. Specification Front Spindle Nuts 42-45 ft. lbs. (57-61 Nm) Rear Spindle Nuts 78-81 ft. lbs. (106-110 Nm) NOTE: All nuts with a cotter pin installed must be s...

139 Maintenance Speed Control Systems 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 50 cc models and under 15 MPH for the 90 cc models. The dealer CANNOT , under any circumstances, either prior to the sale or later...

140 Maintenance Speed Control Systems Electronic Speed Control System Your Polaris ATV is equipped with an electronic speed control system, which controls the engine RPM and speed of the ATV.Speed can be adjusted by removing or installing the jumper on the CDI (A). With the jumper installed, 50cc mo...

141 Maintenance Speed Control Systems Throttle Stop Speed Control System Adjusting speed at the CDI is the recommended method of speed control, but the throttle stop system may also be used. Use the following procedure to control how far the throttle opens.1. Loosen the jam nut (A)2. Turn the screw ...

142 Maintenance Steering Inspection The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV.

143 Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8” to 1/4” toe out.1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. T...

145 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 ″ (1.5mm - 3.2mm) (A). If adjustment is required, turn the adjustment nut (B) until the freeplay falls in to the ...

146 Maintenance Brake Adjustment Periodically check (measure) the freeplay of the front and rear brakes (A). Refer to the specifications chart on page 145 for the acceptable range of freeplay.To adjust the front brake freeplay, turn the adjustment knob (B). To adjust the rear brake freeplay, turn th...

147 Maintenance Air Cleaner Inspect the air filter weekly or after every 50 hours of operation. If the ATV is ridden in wet or dusty conditions, clean the filter more often.1. Remove the screws (A) on the airbox and remove the filter (B). 2. Soak the filter in a mild detergent and rinse it in clean ...

148 Maintenance Carburetor Adjustments 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 ...

149 Maintenance Spark Plugs S Use NGK BP7HS or NGK BPR7HS spark plugs. S Proper electrode gap is .24”-.28” (0.6-0.7 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been wa...

150 Maintenance Spark Plugs NORMAL: 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...

151 Maintenance Cylinder Head/Cylinder Base Fastener Torque Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Gearcase Lubrication The gearcase fill plug (A) is located on the top of the gearcase. The sight glass (B) is...

152 Maintenance Gearcase Oil Change 1. Remove the fill plug.2. Remove the gearcase drain plug and drain the oil into a drain pan. Dispose of properly.3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).4. Add Polaris Premium Synthetic Gearcase Lubricant (about 7 oz.) to the safe zon...

154 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) or less. See illustration. Wheel Removal 1. Stop the engine and lock the parking brake.2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest f...

155 Maintenance Wheel Installation 1. With the park brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2. Install the wheel bolts (A) and finger tighten them. 3. Lower the...

156 Maintenance Drive Chain Inspection and Adjustment Regularly lubricate the drive chain with Polaris chain spray lube or an approved o-ring chain spray lube. See page 170 for the part numbers of Polaris-recommended products. Washing the drive chain with a high pressure washer or gasoline can cause...

157 Maintenance Drive Chain Slack Adjustment 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. Fasten the strap (A) around the axle and rear bumper tube a...

158 Maintenance Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts (A).2. Loosen the chain adjuster lock nut.3. Turn the chain adjuster (B) clockwise to 1/4”-1/2” (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 84 in. lbs. (9.4 Nm). 5. Tighten the four rear hous...

159 Maintenance Brakelight Lamp Replacement If the brakelight doesn’t work, the lamp may need to be replaced.1. From the rear of the brakelight, remove the two screws (A) holding the lens cover in place and remove the lens cover (B). 2. Remove the lamp (C) and replace it with a new recommended lamp....

160 Maintenance Cleaning and Storage Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV The best and safest way to clean your ATV is with a garden ...

161 Maintenance Cleaning and Storage Waxing the ATV Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish. Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when us...

162 Maintenance Cleaning and Storage Storing the ATV Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on engine parts. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged. Use Polaris Fogging Oil and follow the ...

163 Maintenance Cleaning and Storage Transporting the ATV Follow these procedures when transporting the ATV.1. Turn the fuel valve off.2. Be sure the fuel cap, oil cap and seat are installed correctly and securely.3. Tie the frame of the ATV to the transporting unit securely using suitable straps or...

164 Specifications Specifications - Scrambler 50 Rider Capacity/Maximum Weight 1 Rider/90 lbs. (40.9 kg) Displacement 49cc Cooling Fan Cooled Engine type 2-Stroke Lubrication Oil Injected Oil Capacity 1.1 quarts (1 liter) Fuel Capacity 1.3 gallons (5 liters) Starting Electric with kick-start backup ...

166 Specifications Specifications - Scrambler 90 Rider Capacity/Maximum Weight 1 Rider/150 lbs. (68.1 kg) Displacement 89cc Cooling Fan Cooled Engine type 2-Stroke Lubrication Oil Injected Oil Capacity 1.1 quarts (1 liter) Fuel Capacity 1.3 gallons (5 liters) Starting Electric with kick-start backup...

168 Specifications Specifications - Sportsman 90 Rider Capacity/Maximum Weight 1 Rider/150 lbs. (68.1 kg) Displacement 89cc Cooling Fan Cooled Engine type 2-Stroke Lubrication Oil Injected Oil Capacity 1.1 qts. (1 ltr) Fuel Capacity 1.3 ga. (5 ltr) Starting Electric with kick-start backup Transmissi...

170 Polaris-Recommended Products Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602...

172 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 fuel valve to reserve, refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel D...

173 Troubleshooting Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery with .5 amp charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor q...

174 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...

175 Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark 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 p...

176 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...

177 Troubleshooting Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or de...

178 Warranty LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all compo- nents of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year lim- ited warranty on the final drive ch...

179 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 ...

181 Warranty Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris.This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.If an...

182 Index A Air Cleaner 147 . . . . . . . . . . . . . . . . . . . Axle and Wheel Nut Torques 138 . . . . . B Battery 123-125 . . . . . . . . . . . . . . . . . . . Battery Installation 125 . . . . . . . . . . . . . Battery Removal 124 . . . . . . . . . . . . . . . Battery Storage 125 . . . . . . . . ...