Polaris Sportsman 90 - Manuals

v INTRODUCTORY SAFETY MESSAGE TO PARENTS AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles...

viii • Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with exces- sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. N...

ix • Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dis- mount on the uphill side or to either side i...

xi Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.We also advise you to strictly follow the recommended maintenance program outlined in this manual...

xii TABLE OF CONTENTS RIDER’S SECTION R-1 - R-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING WARNINGS 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SAFETY AND DESCRIPTION OF LABELS 5-19 . ...

R--2 KNOW YOUR MACHINE PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride an ATV. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow yo...

R--3 KNOW YOUR MACHINE Pay attention when you see this symbol.: This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you don’t, you could get hurt very badly or even killed. Your safety is in- volved!

R--4 KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine.1. Engine Stop Switch (A) - When the engine is running, you can push this button down to shut the engine off. The button should be up “on” before starting t...

R--5 KNOW YOUR MACHINE 3. Kick Starter (B) - If your battery is too weak to start your machine, you can push on this with your foot to start the engine. Have an adult show you how this works. There is more information on how to use the kickstart on page 69. 3 B

R--6 KNOW YOUR MACHINE 4. Gas Cap - This is where the gas goes that will run your ATV. Your ATV will not run without gas. Only adults should fill the gas tank. 1 4 Always have an adult put gas in your machine.

R--7 KNOW YOUR MACHINE 5. Brake Lever (C) - Squeeze this towards the handle bar to make your ATV slow down or stop. The right hand lever (C-1) controls the front brake. The left hand lever (C-2) controls the rear brake. To slow down or stop, squeeze both brake handles at the same time. 5 C-1 C-2 Alw...

R--8 KNOW YOUR MACHINE 6. Ignition Switch - This key must be turned “on” before pushing the starter button. You can also use this key to turn off the engine. You can find it on the Right-hand side of the Scramblers (D) and on the pod of the Sportsman (E). D E 6

R--9 KNOW YOUR MACHINE 7. Tether Strap/ Switch - This must always be attached snugly to your right wrist and your machine when you are riding. If you fall off your ATV, the tether will pull off the switch and the engine will stop. Put one end of the tether strap around your right wrist. The other en...

R--10 KNOW YOUR MACHINE Let’s review the three ways to stop your ATV. 1. Sliding the shut off switch to the left or right. 2. Disconnecting the tether strap will shut off the engine. 3. Turning the key to off will shut off the engine.

R--12 PRE RIDE CHECK You are almost ready to have an adult start your ATV. Before the ATV is started for the first time, you must do a PRE-RIDE CHECK . In fact, every time you ride your ATV you must have an adult help you check these things before starting it. Let’s learn about these things now. Mak...

R--14 PRE RIDE CHECK Have an adult check the gas level to see if your ATV needs more. Children should never add their own gasoline. This should always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owner’s Manual. Have an ...

R--15 PRE RIDE CHECK This last check is done with the engine running. You must check to make certain that ALL THREE WAYS TO STOP your ATV are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--10 and review.

R--16 RIDING RULES Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remember that safety while you ride is the most important thing. Let’s le...

R--18 RIDING RULES " Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. " Never ride on public trails. " Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on the running b...

R--19 RIDING RULES " Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. " Don’t ride at night. " Learn where there are lakes, rivers, ponds and ditches in your driving area. Sta...

R--20 RIDING RULES " Never follow another ATV too closely. Always allow lots of time and space to stop your ATV. " Only ride your ATV where you know it is safe to drive. No driving over the flower garden or on the little trees you planted. Be careful of the things around you. " Always at...

1 UNDERSTANDING WARNINGS ATTENTION: Always follow the age guidelines on the machine. YOU MUST MAKE CERTAIN THE OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! . It is the parent’s responsibility to teach their children the prope...

2 UNDERSTANDING WARNINGS You should review this information with your child on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, safety training can obtained at no charge from any authorized Polaris dealer.Failure to follow the warnings containe...

3 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! Ind...

4 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: Indicates a potential hazard which may re- sult in minor personal injury or damage to the ATV. NOTE The word “NOTE:” in this manual will alert you to key information or...

5 GENERAL SAFETY AND DESCRIPTION OF LABELS NOTE: Warning decals have been placed on the vehicle for the protection of the operator(s). Read and follow the instructions on each decal carefully. In the event any decal be- comes illegible or comes off, contact your Polaris dealer for a replacement. Any...

7 GENERAL SAFETY AND DESCRIPTION OF LABELS 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 f...

9 GENERAL SAFETY AND DESCRIPTION OF LABELS 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 sure ope...

10 GENERAL SAFETY AND DESCRIPTION OF LABELS 2 Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing control, which could result in severe injury or death. Adult supervision is required. Make sure operators follow Owner’s Manual and labels. Make sure operat...

12 GENERAL SAFETY AND DESCRIPTION OF LABELS IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 3 REAR 3 maximum weight capacity (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS _____ LBS. 3 3 4 WARNING

15 GENERAL SAFETY AND DESCRIPTION OF LABELS ATTENTION D Operation of this vehicle without the filter element will severely dam- age the engine. D Clean air filter often, more frequent cleaning required in dusty conditions. 5 (on rear of seat) 6 D Specific carburetor jetting and adjustments are requi...

19 GENERAL SAFETY AND DESCRIPTION OF LABELS POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVO...

20 DAILY PRE-RIDE INSPECTION Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustment.4...

21 DAILY PRE-RIDE INSPECTION 6. Engine stop switch - check for proper function7. 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 adjustment9. Air cleaner element - check for dirt; cle...

22 OPERATION WARNINGS POTENTIAL HAZARDFailure to follow the age recommendations for this ATV.WHAT CAN HAPPENUse by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.Even though a child may be within the age group for which some ATVs are recommend...

23 OPERATION 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 ope...

24 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV on paved surfaces, including side- walks, 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 o...

29 OPERATION WARNINGS POTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENIncreases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARDNever attempt stunts, such as wheelies or jumps. Don’t try to show off. WARNING

30 OPERATION 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 opera...

31 OPERATION 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, ...

33 OPERATION WARNINGS POTENTIAL HAZARDFailure to use extra care when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENCould cause loss of traction or vehicle control, which could result in an accident, including an overturn.HOW TO AVOID THE HAZARD Do not operate on excessivel...

36 OPERATION WARNINGS POTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in the Owner’s Manual. See page 94. NOTE: A special technique is required wh...

37 OPERATION WARNINGS POTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Ma...

39 OPERATION WARNINGS POTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENYou may lose control of the ATV.You may also regain traction unexpectedly, which may cause the ATV to over- turn.HOW TO AVOID THE HAZARDOn slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the ch...

42 OPERATION WARNINGS POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If you can...

45 OPERATION WARNINGS After a rollover or an accident, have a qualified service dealer check the com- plete machine including, but not limited to, brakes, throttle and steering for possible damage. Safe operation of this rider active vehicle requires good judgement and physi- cal skills. Persons wit...

46 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident.HOW TO AVOID THE HAZARDNever modify this ATV throu...

48 VEHICLE IDENTIFICATION NUMBERS Using the illustration on page 47, record these numbers from your ATV in the spaces provided. 2. Frame VIN (found on the front of frame below steering post) 1. Engine Serial Number (Left side of engine crankcase) Remove the spare key and store in a safe place. Your ...

49 CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1 - Main Switch - Located on the Right-hand side of the Scram- blers (A) and on the pod of the Sportsman (B). This switch is op- erated with a key and must be turned clockwise to the “on” posi- tion to start the engine. A B 1

50 CONTROL AND PARTS FUNCTIONS 2 - Emergency Engine Stop Switch The en- gine will not start or run when the switch is in its “off” position. Its purpose is to provide the operator with a quick means of engine shut- down in case of stuck throttle or other emer- gency. NOTE: Both the main switch and t...

51 CONTROL AND PARTS FUNCTIONS 3 - Engine Start Button - To start the engine, make certain the tether switch is securely plugged into the machine and attached to the rider’s right wrist. Turn the key to the “on” position, set the parking brake, push the start but- ton up to the “on” position and eng...

52 CONTROL AND PARTS FUNCTIONS Engine or driveline damage could occur if the machine is driven without the park brake released. CAUTION This ATV is not equipped with lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced s...

53 CONTROL AND PARTS FUNCTIONS Engine Throttle Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.Always contact your dealer for service repairs whenever throttle...

54 CONTROL AND PARTS FUNCTIONS Throttle Lever Engine speed and vehicle movement are con- trolled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with an Electronic Throttle Control (ETC) whi...

56 CONTROL AND PARTS FUNCTIONS Switches Each Polaris ATV has a main switch. It is located on the right hand side of the machine or headlight pod and operated with a key. Indicator Lights Each Polaris ATV has indicator lights. This model has a low oil warning light. When this red dot is lit, it is in...

57 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes To activate the rear brake (A), squeeze the left hand lever to- ward the handlebar. The front brakes (B) are activated by squeezing the lever on the RH handlebar. A B Always apply both brakes at the same time or loss of vehicle con- trol can occur...

58 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever (A). 2. Push the park brake lock (B) down. This will pre- vent the lever from returning to the released position. Always check to be sure that the parking brake has been disengaged before oper...

59 CONTROL AND PARTS FUNCTIONS 3. To release the parking brake lock, squeeze the brake lever. The parking brake will release automatically. Important Safeguards NOTE: This vehicle has a PVT system which is always in forward. Always lock the park brake before starting the engine. Always lock the park...

61 CONTROL AND PARTS FUNCTIONS Indicates a potential hazard which could result in severe injury or death. WARNING WARNING The engine exhaust from this prod- uct contains chemicals known to cause cancer, birth defects or other reproductive harm.

62 CONTROL AND PARTS FUNCTIONS 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...

63 CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a capac- ity of 1.3 gallons (5 liters). Use unleaded gas- oline with a minimum pump octane number of 87 octane. 1

65 CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter.This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Use only Polaris injection oil. Never substitut...

66 CONTROL AND PARTS FUNCTIONS Oil System The oil tank (1) is located under the seat and has a capacity of 1.1 quarts (1 liter). 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 place and push down on the rear of seat. Always make su...

67 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Po- laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil. Engine war...

68 CONTROL AND PARTS FUNCTIONS Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifi- cally designed for today’s 2-cycle engines. Months of lab and field tests have resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubricants provide additives...

70 STARTING THE ENGINE Procedure for Starting a Cold Engine Indicates a potential hazard which could result in severe injury or death. WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. WARNIN...

71 STARTING THE ENGINE 1. Set the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Attach tether strap to machine and wrist. 5. Turn the engine stop switch to RUN. 6. Turn the ignition key to ON. 7. Press the starter button. NOTE: The rear brake lever must be engaged or th...

72 RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe ridin...

74 VEHICLE 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 gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient perfor...

75 VEHICLE BREAK-IN PERIOD 3. Drive slowly at first. Select an area which is open and will give you room to familiar- ize yourself with vehicle operation and handling. 4. Vary the throttle positions.5. Perform regular checks on fluid levels, controls and all important areas on the ve- hicle as outli...

76 VEHICLE BREAK-IN PERIOD After the break in period the oil injection system provides the necessary engine lu- brication without the need for pre-mixed fuel. After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pu...

77 CARRYING LOADS The Sportsman 90 has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving condi...

78 CARRYING LOADS 2/3 of Load on Rear Rack 1/3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. D CARGO WEIGHT DISTRIBUTION ...

80 CARRYING LOADS D EXTREME CAUTION MUST BE USED when operating with loads ex- tending over the rack sides. Stability and maneuverability may be ad- versely affected, causing the machine to overturn. D DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.

85 RIDING 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 thumb and begin driving. Vehi...

87 RIDING Practice making turns at slow speeds. 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 tr...

88 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or dur- ing cold freezing weather, special attention must be paid to prevent vehicle turnover.

89 RIDING Always: 1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4. Never apply b...

91 RIDING If you have to travel uphill always travel straight uphill and: 1. Avoid steep hills (15 _ maximum). 2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to take emergency action. This m...

93 RIDING Avoid traveling across the side of a hill at all costs. In the event you do enter into a situation where sidehilling is unavoidable, always: 1. Slow down.2. Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests. 3. Steer slightly into the h...

95 RIDING Whenever descending a hill, always: 1. Drive directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the the front and rear brakes at the same time and very slightly to aid in slow- ing. Do not travel at excessive speeds. It is dangerous and can cause los...

96 RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

97 RIDING 1. Stop and lock the parking brake while maintaining body weight uphill.2. Shut off engine.3. Dismount on left or uphill side of ATV.4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).5. While holding service brake, release parking brake lock and slowly allow A...

98 RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the foot- rests.

99 RIDING Before fording streams always: 1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding rocks and obstacles if possible.4. After crossing, dry the brakes by applying light pressure to the levers until braking action is no...

103 RIDING Whenever the Vehicle is Parked 1. Turn the engine off.2. Set the parking brake.3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown on the facing page. 4. Shut off fuel supply.

104 PVT SYSTEM OPERATION 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 fol- lowing responsibilities to make sure thi...

105 PVT SYSTEM OPERATION If the vehicle is operated in dusty areas, it will be necessary to clean the filter more often. To clean the PVT filter: 1. Remove the screws and the crankcase cover. 2. Remove the screws and the filter cover. 3. Soak the filter in a mild detergent and rinse with clean water...

106 BATTERY Battery Only adults should ever touch the battery. Never allow children to handle a battery or service a battery in any way. WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an ex...

107 BATTERY Indicates a potential hazard which could result in severe injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of wat...

108 BATTERY Replenishing the Battery Fluid 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.To refill use only distilled water. Tap water contains minerals which are harmful to a battery....

109 BATTERY Battery Removal 1. Disconnect hold down straps holding 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, being careful not to tip it sideways and spill...

110 BATTERY Battery Installation and Connections Battery terminals and connections should be kept free of corrosion.If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solu- tion of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off wi...

112 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...

113 NOISE EMISSION CONTROL SYSTEM REGULATION 2. Removal or alteration or the puncturing of any part of the engine air induction system. 3. Replacement of any vehicle parts with parts not in compliance with federal regulations. 4. Lack of proper maintenance. D Be careful when traveling through tall g...

114 NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

115 MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compart- ment under the seat. Items included in the kits are: 2-cycle engines D spark plug wrench with Phillips head screwdriver D tire pressure gauge Periodic Maintenance Schedule Careful period...

116 MAINTENANCE Maintenance intervals are based upon average riding conditions and an average ve- hicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more fre- quently. If you are not familiar wit...

117 MAINTENANCE " More often under severe use, such as dirty or wet conditions Item Hours or Miles When Remarks Brake System Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bo...

122 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil Polaris Injection Oil Fill oil tank. See page 63. As needed, when refuel- ing 2. Transmission Oil Polaris Premium Synthetic gear case lube See Page 148 Change annually or at 100 hours

123 MAINTENANCE Lubrication Recommendations Operating Range 2. Transmission (plug)

124 MAINTENANCE 3. Drive Chain O-Ring chain lube or SAE 80/90 Lubricate as often as re- quired. Before each ride in wet conditions As required 4. Front A-Arm L Grease ** Locate fittings and grease Every 3 months or 50 hours L More often under severe use, such as wet or dusty conditions. **Polaris Pr...

125 MAINTENANCE NOTE: Hours are based on 10 mph average. 4.

126 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs.50 Hrs.75 Hrs. 100 Hrs.

128 MAINTENANCE Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to remove the upper “headlight” pod. On other models remove the handlebar cover. Improper adjustment of the handle...

130 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Specification Front Spindle Nuts 43 ft. lbs Rear Spindle Nuts 80 ft. lbs. NOTE: All nuts that have a cotter pin installed ...

131 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction re- quired to increase or decrease spring ten- sion. Rear Spring Adjustment Cam

132 MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation. If the vehicle is ridden in wet or dusty conditions, clean the filter more often. Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the...

133 MAINTENANCE To clean the filter: 1. Remove the screws on the airbox (A) and re- move the filter (B). 2. Soak the filter in a mild detergent and rinse it in clean water. 3. Let the filter air dry and reinstall in the air box. A B

134 MAINTENANCE Throttle Stop System The throttle stop system controls how far the throttle opens. To adjust, loos- en the jam nut (D), turn the screw (E) inward to reduce speed and outward to increase speed. Tighten the jam nut after adjusting. D E

135 MAINTENANCE Exhaust System Restrictor The exhaust restrictor system restricts exhaust gas flow, reducing the maximum power output of the engine. Exhaust System Restrictor Removal The Scrambler 50 utilizes a restrictor at the headpipe exhaust flange and at the spark arrestor. Make certain the eng...

136 MAINTENANCE Lower the exhaust system and remove the restrictor washer (A). Re-install the head pipe exhaust flange nuts, the center mount bolt, and the spark arrestor fasteners. Torque the spark arres- tor first, then the center mount bolt and the head pipe flange nuts last. Torque to 10 ft. lbs...

137 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. Do not attempt to...

138 MAINTENANCE Toe Alignment You can check the toe alignment of the ve- hicle using the following method. The rec- ommended toe alignment is 1/8 ″ to 1/4 ″ (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1. Set the handlebars in a straight ahead position and ...

140 140MAINTENANCE Brake Adjustment Periodically check the freeplay of the front and rear brakes. Refer to the chart below for the acceptable range of freeplay for your ma- chine. To adjust the front brake, turn the adjustment knob (A) until the freeplay is acceptable. A

141 MAINTENANCE To adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is attained. B

142 MAINTENANCE Brake Freeplay Adjustment Model Front Rear Sportsman 90 .39 ″ - .78 ″ 10 mm - 20 mm .39 ″ - .78 ″ 10 mm - 20 mm Scrambler 90 .39 ″ - .78 ″ 10 mm - 20 mm .39 ″ - .78 ″ 10 mm - 20 mm Scrambler 50 .1 ″ - .39 ″ 2.5mm - 9.9 mm .15 ″ - .30 ″ 3.8mm - 7.6mm

143 MAINTENANCE Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept between 1/16 ″ and 1/8 ″ (1.5mm - 3.2mm) (C). If adjustment is required, turn the adjustment nut (D) until the freeplay falls in to the ...

144 MAINTENANCE Spark Plugs The spark plug required for this machine is NGK BP7HS or NGK BPR7HS. Incorrect spark plug gap can cause the spark plugs to foul. The spark plug gap should be be- tween 0.6 - 0.7 mm.The spark plug and its condition is indicative of engine operation. The spark plug firing e...

145 MAINTENANCE 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect c...

146 MAINTENANCE Storage Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion of engine parts.Whenever the machine is stored for a period of more than 60 days, the engine must be fogged, following the fogging instructions on the can.Always add a fuel condi...

147 MAINTENANCE Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Indicates a potential hazard which could result in severe injury or death. WARNING

148 MAINTENANCE Transmission Lubrication The transmission dipstick (A) is located on the top of the transmission.The transmission lubricant level should be checked monthly. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug dipstick and check the lubricant...

149 MAINTENANCE Transmission Oil Changing Procedure 1. Remove fill plug/dipstick. 2. Remove transmission drain plug and drain the oil. Catch and discard used oil prop- erly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to ful...

150 MAINTENANCE Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. WARNI...

151 MAINTENANCE Important Safeguards Maintain proper tire pressure according to chartson page 152. Improper tire inflation may affect ATV maneuverability. Do not use improper tires. The use of non-standard size or type tires may affect ATV handling. Make certain the wheels are installed properly. If...

152 MAINTENANCE Tire Size PSI Wheel Nut Torque Scrambler 50 Front 16 x 8 - 7 2 22 ft. lbs Rear 16 x 8 - 7 2 22 ft. lbs Scrambler 90 Front 18 x 7 - 7 3 22 ft. lbs Rear 18 x 9.5 - 8 3 22 ft. lbs Sportsman 90 Front 19 x 7 - 8 3 22 ft. lbs Rear 18 x 9.5 - 8 3 22 ft. lbs

153 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. Attach the wheel nuts and finger tighten them. 3. Lower the vehic...

154 MAINTENANCE Tire Inspection When replacing a tire always use original equip- ment size and type. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) (1) or less. 1

155 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. Regularly lubricate the drive chain with SAE 80-90 lube or an approved O-...

157 MAINTENANCE Rear Drive Chain Slack Adjustment The normal chain slack should be kept between .40 ″ - .80 ″ 〈 10-20 mm) (A). Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. CAUTION 1 A

158 MAINTENANCE Adjustment Procedure 1. Loosen 4 rear housing mount bolts (A). 2. Tighten chain adjuster (B) to reduce slack to recommended setting. (.4 ″ - .8 ″ / 10 mm - 20 mm) 3. Tighten jam nuts on chain adjuster. 4. Tighten the four rear housing mount bolts. A B

159 MAINTENANCE Brakelight Lamp Replacement If the brakelight does not work the lamp may need to be replaced. 1. From the rear of the brake light remove two screws (A) holding lens cover in place and remove lens cover (B). 2. Remove lamp (C) and replace it with recom- mended lamp. 3. Test the brakel...

160 MAINTENANCE Cleaning Your 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 much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be ...

161 MAINTENANCE The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warni...

162 MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off.2. Be certain the fuel cap, oil cap, and seat are installed correctly. 3. Always tie the frame of the ATV to the transporting unit securely using suitable straps o...

163 MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjust- ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of it...

164 SPECIFICATIONS Specifications - Scrambler 50 Rider Capacity 1 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 Transmission Automatic CVT Front Suspen...

166 SPECIFICATIONS Specifications - Scrambler 90 Rider Capacity 1 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 Transmission Automatic CVT Front Suspen...

168 SPECIFICATIONS Specifications - Sportsman 90 Rider Capacity 1 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 Transmission Automatic CVT Front Suspension A-arm ...

170 SPECIFICATIONS Specifications - Sportsman 90 Low Oil Light Standard Front Rack Capacity 10 lb (4.5 kgs) Rear Rack Capacity 20 lb (9 kgs) Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polar- is dealer to find out about the accessories available for you...

173 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plu...

175 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 war- ranty on the final drive chai...

176 WARRANTY REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PRO...

177 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 ...

179 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR- POSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PE- RIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some sta...

180 WARRANTY Please work with your dealer to resolve any warranty issues. Should your dealer re- quire any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If a...

181 INDEX Air Cleaner 132 . . . . . . . . . . . . . . . . . . . Battery Installation 110 . . . . . . . . . . . . . Battery Maintenance 106 . . . . . . . . . . . Battery Removal 109 . . . . . . . . . . . . . . Brake Adjustment 140 . . . . . . . . . . . . . Brake Freeplay Adjustment 142 . . . . . Brak...

Part No. 9917080 Improper ATV use can result in SEVERE INJURY or DEATH Always use an approved helmet and protective gear Never use on public roads Never carry passengers Never use with drugs or alcohol NEVER operate: without proper training or instruction; at speeds too fast for your skills or the c...

v INTRODUCTORY SAFETY MESSAGE TO PARENTS AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles...

viii • Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with exces- sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. N...

ix • Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dis- mount on the uphill side or to either side i...

xi Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.We also advise you to strictly follow the recommended maintenance program outlined in this manual...

xii TABLE OF CONTENTS RIDER’S SECTION R-1 - R-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDERSTANDING WARNINGS 1 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SAFETY AND DESCRIPTION OF LABELS 5-19 . ...

R--2 KNOW YOUR MACHINE PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride an ATV. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow yo...

R--3 KNOW YOUR MACHINE Pay attention when you see this symbol.: This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you don’t, you could get hurt very badly or even killed. Your safety is in- volved!

R--4 KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine.1. Engine Stop Switch (A) - When the engine is running, you can push this button down to shut the engine off. The button should be up “on” before starting t...

R--5 KNOW YOUR MACHINE 3. Kick Starter (B) - If your battery is too weak to start your machine, you can push on this with your foot to start the engine. Have an adult show you how this works. There is more information on how to use the kickstart on page 69. 3 B

R--6 KNOW YOUR MACHINE 4. Gas Cap - This is where the gas goes that will run your ATV. Your ATV will not run without gas. Only adults should fill the gas tank. 1 4 Always have an adult put gas in your machine.

R--7 KNOW YOUR MACHINE 5. Brake Lever (C) - Squeeze this towards the handle bar to make your ATV slow down or stop. The right hand lever (C-1) controls the front brake. The left hand lever (C-2) controls the rear brake. To slow down or stop, squeeze both brake handles at the same time. 5 C-1 C-2 Alw...

R--8 KNOW YOUR MACHINE 6. Ignition Switch - This key must be turned “on” before pushing the starter button. You can also use this key to turn off the engine. You can find it on the Right-hand side of the Scramblers (D) and on the pod of the Sportsman (E). D E 6

R--9 KNOW YOUR MACHINE 7. Tether Strap/ Switch - This must always be attached snugly to your right wrist and your machine when you are riding. If you fall off your ATV, the tether will pull off the switch and the engine will stop. Put one end of the tether strap around your right wrist. The other en...

R--10 KNOW YOUR MACHINE Let’s review the three ways to stop your ATV. 1. Sliding the shut off switch to the left or right. 2. Disconnecting the tether strap will shut off the engine. 3. Turning the key to off will shut off the engine.

R--12 PRE RIDE CHECK You are almost ready to have an adult start your ATV. Before the ATV is started for the first time, you must do a PRE-RIDE CHECK . In fact, every time you ride your ATV you must have an adult help you check these things before starting it. Let’s learn about these things now. Mak...

R--14 PRE RIDE CHECK Have an adult check the gas level to see if your ATV needs more. Children should never add their own gasoline. This should always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owner’s Manual. Have an ...

R--15 PRE RIDE CHECK This last check is done with the engine running. You must check to make certain that ALL THREE WAYS TO STOP your ATV are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--10 and review.

R--16 RIDING RULES Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remember that safety while you ride is the most important thing. Let’s le...

R--18 RIDING RULES " Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. " Never ride on public trails. " Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on the running b...

R--19 RIDING RULES " Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. " Don’t ride at night. " Learn where there are lakes, rivers, ponds and ditches in your driving area. Sta...

R--20 RIDING RULES " Never follow another ATV too closely. Always allow lots of time and space to stop your ATV. " Only ride your ATV where you know it is safe to drive. No driving over the flower garden or on the little trees you planted. Be careful of the things around you. " Always at...

1 UNDERSTANDING WARNINGS ATTENTION: Always follow the age guidelines on the machine. YOU MUST MAKE CERTAIN THE OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! . It is the parent’s responsibility to teach their children the prope...

2 UNDERSTANDING WARNINGS You should review this information with your child on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, safety training can obtained at no charge from any authorized Polaris dealer.Failure to follow the warnings containe...

3 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! Ind...

4 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: Indicates a potential hazard which may re- sult in minor personal injury or damage to the ATV. NOTE The word “NOTE:” in this manual will alert you to key information or...

5 GENERAL SAFETY AND DESCRIPTION OF LABELS NOTE: Warning decals have been placed on the vehicle for the protection of the operator(s). Read and follow the instructions on each decal carefully. In the event any decal be- comes illegible or comes off, contact your Polaris dealer for a replacement. Any...

7 GENERAL SAFETY AND DESCRIPTION OF LABELS 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 f...

9 GENERAL SAFETY AND DESCRIPTION OF LABELS 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 sure ope...

10 GENERAL SAFETY AND DESCRIPTION OF LABELS 2 Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing control, which could result in severe injury or death. Adult supervision is required. Make sure operators follow Owner’s Manual and labels. Make sure operat...

12 GENERAL SAFETY AND DESCRIPTION OF LABELS IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 3 REAR 3 maximum weight capacity (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS _____ LBS. 3 3 4 WARNING

15 GENERAL SAFETY AND DESCRIPTION OF LABELS ATTENTION D Operation of this vehicle without the filter element will severely dam- age the engine. D Clean air filter often, more frequent cleaning required in dusty conditions. 5 (on rear of seat) 6 D Specific carburetor jetting and adjustments are requi...

19 GENERAL SAFETY AND DESCRIPTION OF LABELS POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVO...

20 DAILY PRE-RIDE INSPECTION Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustment.4...

21 DAILY PRE-RIDE INSPECTION 6. Engine stop switch - check for proper function7. 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 adjustment9. Air cleaner element - check for dirt; cle...

22 OPERATION WARNINGS POTENTIAL HAZARDFailure to follow the age recommendations for this ATV.WHAT CAN HAPPENUse by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.Even though a child may be within the age group for which some ATVs are recommend...

23 OPERATION 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 ope...

24 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV on paved surfaces, including side- walks, 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 o...

29 OPERATION WARNINGS POTENTIAL HAZARDAttempting wheelies, jumps and other stunts.WHAT CAN HAPPENIncreases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARDNever attempt stunts, such as wheelies or jumps. Don’t try to show off. WARNING

30 OPERATION 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 opera...

31 OPERATION 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, ...

33 OPERATION WARNINGS POTENTIAL HAZARDFailure to use extra care when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENCould cause loss of traction or vehicle control, which could result in an accident, including an overturn.HOW TO AVOID THE HAZARD Do not operate on excessivel...

36 OPERATION WARNINGS POTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in the Owner’s Manual. See page 94. NOTE: A special technique is required wh...

37 OPERATION WARNINGS POTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Ma...

39 OPERATION WARNINGS POTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENYou may lose control of the ATV.You may also regain traction unexpectedly, which may cause the ATV to over- turn.HOW TO AVOID THE HAZARDOn slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the ch...

42 OPERATION WARNINGS POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If you can...

45 OPERATION WARNINGS After a rollover or an accident, have a qualified service dealer check the com- plete machine including, but not limited to, brakes, throttle and steering for possible damage. Safe operation of this rider active vehicle requires good judgement and physi- cal skills. Persons wit...

46 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident.HOW TO AVOID THE HAZARDNever modify this ATV throu...

48 VEHICLE IDENTIFICATION NUMBERS Using the illustration on page 47, record these numbers from your ATV in the spaces provided. 2. Frame VIN (found on the front of frame below steering post) 1. Engine Serial Number (Left side of engine crankcase) Remove the spare key and store in a safe place. Your ...

49 CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1 - Main Switch - Located on the Right-hand side of the Scram- blers (A) and on the pod of the Sportsman (B). This switch is op- erated with a key and must be turned clockwise to the “on” posi- tion to start the engine. A B 1

50 CONTROL AND PARTS FUNCTIONS 2 - Emergency Engine Stop Switch The en- gine will not start or run when the switch is in its “off” position. Its purpose is to provide the operator with a quick means of engine shut- down in case of stuck throttle or other emer- gency. NOTE: Both the main switch and t...

51 CONTROL AND PARTS FUNCTIONS 3 - Engine Start Button - To start the engine, make certain the tether switch is securely plugged into the machine and attached to the rider’s right wrist. Turn the key to the “on” position, set the parking brake, push the start but- ton up to the “on” position and eng...

52 CONTROL AND PARTS FUNCTIONS Engine or driveline damage could occur if the machine is driven without the park brake released. CAUTION This ATV is not equipped with lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced s...

53 CONTROL AND PARTS FUNCTIONS Engine Throttle Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.Always contact your dealer for service repairs whenever throttle...

54 CONTROL AND PARTS FUNCTIONS Throttle Lever Engine speed and vehicle movement are con- trolled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with an Electronic Throttle Control (ETC) whi...

56 CONTROL AND PARTS FUNCTIONS Switches Each Polaris ATV has a main switch. It is located on the right hand side of the machine or headlight pod and operated with a key. Indicator Lights Each Polaris ATV has indicator lights. This model has a low oil warning light. When this red dot is lit, it is in...

57 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes To activate the rear brake (A), squeeze the left hand lever to- ward the handlebar. The front brakes (B) are activated by squeezing the lever on the RH handlebar. A B Always apply both brakes at the same time or loss of vehicle con- trol can occur...

58 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever (A). 2. Push the park brake lock (B) down. This will pre- vent the lever from returning to the released position. Always check to be sure that the parking brake has been disengaged before oper...

59 CONTROL AND PARTS FUNCTIONS 3. To release the parking brake lock, squeeze the brake lever. The parking brake will release automatically. Important Safeguards NOTE: This vehicle has a PVT system which is always in forward. Always lock the park brake before starting the engine. Always lock the park...

61 CONTROL AND PARTS FUNCTIONS Indicates a potential hazard which could result in severe injury or death. WARNING WARNING The engine exhaust from this prod- uct contains chemicals known to cause cancer, birth defects or other reproductive harm.

62 CONTROL AND PARTS FUNCTIONS 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...

63 CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a capac- ity of 1.3 gallons (5 liters). Use unleaded gas- oline with a minimum pump octane number of 87 octane. 1

65 CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter.This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Use only Polaris injection oil. Never substitut...

66 CONTROL AND PARTS FUNCTIONS Oil System The oil tank (1) is located under the seat and has a capacity of 1.1 quarts (1 liter). 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 place and push down on the rear of seat. Always make su...

67 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Po- laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil. Engine war...

68 CONTROL AND PARTS FUNCTIONS Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifi- cally designed for today’s 2-cycle engines. Months of lab and field tests have resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubricants provide additives...

70 STARTING THE ENGINE Procedure for Starting a Cold Engine Indicates a potential hazard which could result in severe injury or death. WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. WARNIN...

71 STARTING THE ENGINE 1. Set the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Attach tether strap to machine and wrist. 5. Turn the engine stop switch to RUN. 6. Turn the ignition key to ON. 7. Press the starter button. NOTE: The rear brake lever must be engaged or th...

72 RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe ridin...

74 VEHICLE 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 gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient perfor...

75 VEHICLE BREAK-IN PERIOD 3. Drive slowly at first. Select an area which is open and will give you room to familiar- ize yourself with vehicle operation and handling. 4. Vary the throttle positions.5. Perform regular checks on fluid levels, controls and all important areas on the ve- hicle as outli...

76 VEHICLE BREAK-IN PERIOD After the break in period the oil injection system provides the necessary engine lu- brication without the need for pre-mixed fuel. After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pu...

77 CARRYING LOADS The Sportsman 90 has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving condi...

78 CARRYING LOADS 2/3 of Load on Rear Rack 1/3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. D CARGO WEIGHT DISTRIBUTION ...

80 CARRYING LOADS D EXTREME CAUTION MUST BE USED when operating with loads ex- tending over the rack sides. Stability and maneuverability may be ad- versely affected, causing the machine to overturn. D DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.

85 RIDING 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 thumb and begin driving. Vehi...

87 RIDING Practice making turns at slow speeds. 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 tr...

88 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or dur- ing cold freezing weather, special attention must be paid to prevent vehicle turnover.

89 RIDING Always: 1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4. Never apply b...

91 RIDING If you have to travel uphill always travel straight uphill and: 1. Avoid steep hills (15 _ maximum). 2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to take emergency action. This m...

93 RIDING Avoid traveling across the side of a hill at all costs. In the event you do enter into a situation where sidehilling is unavoidable, always: 1. Slow down.2. Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests. 3. Steer slightly into the h...

95 RIDING Whenever descending a hill, always: 1. Drive directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the the front and rear brakes at the same time and very slightly to aid in slow- ing. Do not travel at excessive speeds. It is dangerous and can cause los...

96 RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

97 RIDING 1. Stop and lock the parking brake while maintaining body weight uphill.2. Shut off engine.3. Dismount on left or uphill side of ATV.4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).5. While holding service brake, release parking brake lock and slowly allow A...

98 RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the foot- rests.

99 RIDING Before fording streams always: 1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding rocks and obstacles if possible.4. After crossing, dry the brakes by applying light pressure to the levers until braking action is no...

103 RIDING Whenever the Vehicle is Parked 1. Turn the engine off.2. Set the parking brake.3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown on the facing page. 4. Shut off fuel supply.

104 PVT SYSTEM OPERATION 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 fol- lowing responsibilities to make sure thi...

105 PVT SYSTEM OPERATION If the vehicle is operated in dusty areas, it will be necessary to clean the filter more often. To clean the PVT filter: 1. Remove the screws and the crankcase cover. 2. Remove the screws and the filter cover. 3. Soak the filter in a mild detergent and rinse with clean water...

106 BATTERY Battery Only adults should ever touch the battery. Never allow children to handle a battery or service a battery in any way. WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an ex...

107 BATTERY Indicates a potential hazard which could result in severe injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of wat...

108 BATTERY Replenishing the Battery Fluid 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.To refill use only distilled water. Tap water contains minerals which are harmful to a battery....

109 BATTERY Battery Removal 1. Disconnect hold down straps holding 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, being careful not to tip it sideways and spill...

110 BATTERY Battery Installation and Connections Battery terminals and connections should be kept free of corrosion.If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solu- tion of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off wi...

112 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...

113 NOISE EMISSION CONTROL SYSTEM REGULATION 2. Removal or alteration or the puncturing of any part of the engine air induction system. 3. Replacement of any vehicle parts with parts not in compliance with federal regulations. 4. Lack of proper maintenance. D Be careful when traveling through tall g...

114 NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

115 MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compart- ment under the seat. Items included in the kits are: 2-cycle engines D spark plug wrench with Phillips head screwdriver D tire pressure gauge Periodic Maintenance Schedule Careful period...

116 MAINTENANCE Maintenance intervals are based upon average riding conditions and an average ve- hicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more fre- quently. If you are not familiar wit...

117 MAINTENANCE " More often under severe use, such as dirty or wet conditions Item Hours or Miles When Remarks Brake System Pre-ride Pre-ride Pre-ride inspection item Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item Wheels Pre-ride Pre-ride Pre-ride inspection item Frame nuts, bo...

122 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil Polaris Injection Oil Fill oil tank. See page 63. As needed, when refuel- ing 2. Transmission Oil Polaris Premium Synthetic gear case lube See Page 148 Change annually or at 100 hours

123 MAINTENANCE Lubrication Recommendations Operating Range 2. Transmission (plug)

124 MAINTENANCE 3. Drive Chain O-Ring chain lube or SAE 80/90 Lubricate as often as re- quired. Before each ride in wet conditions As required 4. Front A-Arm L Grease ** Locate fittings and grease Every 3 months or 50 hours L More often under severe use, such as wet or dusty conditions. **Polaris Pr...

125 MAINTENANCE NOTE: Hours are based on 10 mph average. 4.

126 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs.50 Hrs.75 Hrs. 100 Hrs.

128 MAINTENANCE Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to remove the upper “headlight” pod. On other models remove the handlebar cover. Improper adjustment of the handle...

130 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Specification Front Spindle Nuts 43 ft. lbs Rear Spindle Nuts 80 ft. lbs. NOTE: All nuts that have a cotter pin installed ...

131 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction re- quired to increase or decrease spring ten- sion. Rear Spring Adjustment Cam

132 MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation. If the vehicle is ridden in wet or dusty conditions, clean the filter more often. Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the...

133 MAINTENANCE To clean the filter: 1. Remove the screws on the airbox (A) and re- move the filter (B). 2. Soak the filter in a mild detergent and rinse it in clean water. 3. Let the filter air dry and reinstall in the air box. A B

134 MAINTENANCE Throttle Stop System The throttle stop system controls how far the throttle opens. To adjust, loos- en the jam nut (D), turn the screw (E) inward to reduce speed and outward to increase speed. Tighten the jam nut after adjusting. D E

135 MAINTENANCE Exhaust System Restrictor The exhaust restrictor system restricts exhaust gas flow, reducing the maximum power output of the engine. Exhaust System Restrictor Removal The Scrambler 50 utilizes a restrictor at the headpipe exhaust flange and at the spark arrestor. Make certain the eng...

136 MAINTENANCE Lower the exhaust system and remove the restrictor washer (A). Re-install the head pipe exhaust flange nuts, the center mount bolt, and the spark arrestor fasteners. Torque the spark arres- tor first, then the center mount bolt and the head pipe flange nuts last. Torque to 10 ft. lbs...

137 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. Do not attempt to...

138 MAINTENANCE Toe Alignment You can check the toe alignment of the ve- hicle using the following method. The rec- ommended toe alignment is 1/8 ″ to 1/4 ″ (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1. Set the handlebars in a straight ahead position and ...

140 140MAINTENANCE Brake Adjustment Periodically check the freeplay of the front and rear brakes. Refer to the chart below for the acceptable range of freeplay for your ma- chine. To adjust the front brake, turn the adjustment knob (A) until the freeplay is acceptable. A

141 MAINTENANCE To adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is attained. B

142 MAINTENANCE Brake Freeplay Adjustment Model Front Rear Sportsman 90 .39 ″ - .78 ″ 10 mm - 20 mm .39 ″ - .78 ″ 10 mm - 20 mm Scrambler 90 .39 ″ - .78 ″ 10 mm - 20 mm .39 ″ - .78 ″ 10 mm - 20 mm Scrambler 50 .1 ″ - .39 ″ 2.5mm - 9.9 mm .15 ″ - .30 ″ 3.8mm - 7.6mm

143 MAINTENANCE Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept between 1/16 ″ and 1/8 ″ (1.5mm - 3.2mm) (C). If adjustment is required, turn the adjustment nut (D) until the freeplay falls in to the ...

144 MAINTENANCE Spark Plugs The spark plug required for this machine is NGK BP7HS or NGK BPR7HS. Incorrect spark plug gap can cause the spark plugs to foul. The spark plug gap should be be- tween 0.6 - 0.7 mm.The spark plug and its condition is indicative of engine operation. The spark plug firing e...

145 MAINTENANCE 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect c...

146 MAINTENANCE Storage Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion of engine parts.Whenever the machine is stored for a period of more than 60 days, the engine must be fogged, following the fogging instructions on the can.Always add a fuel condi...

147 MAINTENANCE Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Indicates a potential hazard which could result in severe injury or death. WARNING

148 MAINTENANCE Transmission Lubrication The transmission dipstick (A) is located on the top of the transmission.The transmission lubricant level should be checked monthly. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug dipstick and check the lubricant...

149 MAINTENANCE Transmission Oil Changing Procedure 1. Remove fill plug/dipstick. 2. Remove transmission drain plug and drain the oil. Catch and discard used oil prop- erly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to ful...

150 MAINTENANCE Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. WARNI...

151 MAINTENANCE Important Safeguards Maintain proper tire pressure according to chartson page 152. Improper tire inflation may affect ATV maneuverability. Do not use improper tires. The use of non-standard size or type tires may affect ATV handling. Make certain the wheels are installed properly. If...

152 MAINTENANCE Tire Size PSI Wheel Nut Torque Scrambler 50 Front 16 x 8 - 7 2 22 ft. lbs Rear 16 x 8 - 7 2 22 ft. lbs Scrambler 90 Front 18 x 7 - 7 3 22 ft. lbs Rear 18 x 9.5 - 8 3 22 ft. lbs Sportsman 90 Front 19 x 7 - 8 3 22 ft. lbs Rear 18 x 9.5 - 8 3 22 ft. lbs

153 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. Attach the wheel nuts and finger tighten them. 3. Lower the vehic...

154 MAINTENANCE Tire Inspection When replacing a tire always use original equip- ment size and type. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (.3 cm) (1) or less. 1

155 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. Regularly lubricate the drive chain with SAE 80-90 lube or an approved O-...

157 MAINTENANCE Rear Drive Chain Slack Adjustment The normal chain slack should be kept between .40 ″ - .80 ″ 〈 10-20 mm) (A). Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. CAUTION 1 A

158 MAINTENANCE Adjustment Procedure 1. Loosen 4 rear housing mount bolts (A). 2. Tighten chain adjuster (B) to reduce slack to recommended setting. (.4 ″ - .8 ″ / 10 mm - 20 mm) 3. Tighten jam nuts on chain adjuster. 4. Tighten the four rear housing mount bolts. A B

159 MAINTENANCE Brakelight Lamp Replacement If the brakelight does not work the lamp may need to be replaced. 1. From the rear of the brake light remove two screws (A) holding lens cover in place and remove lens cover (B). 2. Remove lamp (C) and replace it with recom- mended lamp. 3. Test the brakel...

160 MAINTENANCE Cleaning Your 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 much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be ...

161 MAINTENANCE The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warni...

162 MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off.2. Be certain the fuel cap, oil cap, and seat are installed correctly. 3. Always tie the frame of the ATV to the transporting unit securely using suitable straps o...

163 MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjust- ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of it...

164 SPECIFICATIONS Specifications - Scrambler 50 Rider Capacity 1 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 Transmission Automatic CVT Front Suspen...

166 SPECIFICATIONS Specifications - Scrambler 90 Rider Capacity 1 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 Transmission Automatic CVT Front Suspen...

168 SPECIFICATIONS Specifications - Sportsman 90 Rider Capacity 1 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 Transmission Automatic CVT Front Suspension A-arm ...

170 SPECIFICATIONS Specifications - Sportsman 90 Low Oil Light Standard Front Rack Capacity 10 lb (4.5 kgs) Rear Rack Capacity 20 lb (9 kgs) Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polar- is dealer to find out about the accessories available for you...

173 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plu...

175 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 war- ranty on the final drive chai...

176 WARRANTY REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PRO...

177 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 ...

179 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR- POSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PE- RIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some sta...

180 WARRANTY Please work with your dealer to resolve any warranty issues. Should your dealer re- quire any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. If a...

181 INDEX Air Cleaner 132 . . . . . . . . . . . . . . . . . . . Battery Installation 110 . . . . . . . . . . . . . Battery Maintenance 106 . . . . . . . . . . . Battery Removal 109 . . . . . . . . . . . . . . Brake Adjustment 140 . . . . . . . . . . . . . Brake Freeplay Adjustment 142 . . . . . Brak...

Part No. 9917080 Improper ATV use can result in SEVERE INJURY or DEATH Always use an approved helmet and protective gear Never use on public roads Never carry passengers Never use with drugs or alcohol NEVER operate: without proper training or instruction; at speeds too fast for your skills or the c...