Polaris 9921483 - Manual

6 Safety Understand the Warnings Always follow the age guidelines for your ATV. Never allow a younger child to ride on or drive the ATV. Make sure all operators have completed an approved ATV safety training course such as the SVIA RiderCourse sm and understand all warnings and the owner's manual be...

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

8 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 ...

10 Safety • Read this manual and all labels carefully. Follow all operating procedures. • Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and age eli- gible family members are entitled to take the ATV RiderCourse sm . Contact ATV Enrollment ...

14 Safety • Always check for obstacles before oper- ating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Avoid operating the ATV through deep or fast flowing wat...

15 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...

18 Know Your ATV PARENTS: Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experience. More information on speed limiting functions can be found beginning on page 142.These units are not designed for adult use. Se...

19 Know Your ATV Before you have an adult start the engine for you for the first time, let's learn about the con- trols on your new ATV.1. Engine Stop Switch - When the engine is running, push this button down to shut the engine off quickly. The button must be up before you can start the engine agai...

20 Know Your ATV 4. Kick-Start Lever - If your battery is too weak to start your ATV, you can push down on the kick-start lever with your foot to start the engine. Have an adult show you how it works. Read more about how to use the kick-start on page 82. 5. Shift Lever - The shift lever is on the ri...

21 Know Your ATV 6. Gas Cap - The gas cap has to be taken off when an adult puts gas in your ATV. Never take the gas cap off. Always make sure it's tightly closed. Always have an adult put gas in your ATV. Never try to do it yourself. 7. Seat Latch - The seat latch is under the left edge of the seat...

22 Know Your ATV 8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you...

23 Know Your ATV 9. Ignition Switch - The ignition switch key must be turned on before pushing the starter button. You can also use this key to turn off the engine. 10. Tether Strap and Switch - The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive....

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

25 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 ...

26 Pre-Ride Check n Make sure the brakes don't stick. Check the brake levers by squeezing them toward the handlebar and then letting go. They should come right back to where they were before you squeezed. If they go back slowly or stay close to the handlebar, your ATV has sticky brakes. They must be...

28 Riding Rules Now you're ready to learn about riding your Polaris ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride. X The adult with you is...

29 Riding Rules X Always wear the right kind of clothing and safety gear when riding your ATV. Helmet: Your helmet is very important for safe riding. A helmet can prevent a severe head injury. Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you...

31 Riding Rules X Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. X Never ride on public trails. X Don't ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or tra...

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

34 Safety Decals Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV.If any decal becom...

35 Safety Decals Operation Warning WARNINGImproper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear. Never use on public roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: without proper training or instruction; at speeds too...

36 Safety Decals Age Warning WARNING • Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing con- trol, which could result in severe injury or death. • Adult supervision is required.• Make sure operators follow Owner's Manual and labels.• Make sure operato...

37 Safety Decals Outlaw 90 Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7) REAR 3 (20.7)MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS ...

38 Safety Decals Sportsman 90 Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7) REAR 3 (20.7)MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO I...

39 Safety Decals No Passenger Warning WARNING NEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. + +

40 Safety Decals Sportsman 90 Rack Warning WARNING DO NOT TOW WITH THIS VEHICLE.Vehicle damage or tipover may result causing severe injury or death. Maximum Rack Loads: Front 15 lbs. (6.8 kg) Rear 30 lbs. (13.6 kg) + +

41 Safety Decals Clutch Cover Warning WARNINGNO STEP Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.Do not touch clutch cover, cover may become hot.Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, ...

43 Driver Warnings Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child's safety. Be sure to explain to your young driver that the following hazards MUST be avoided at all times.

44 Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beg...

45 Driver Warnings WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child.Even though a child may be within the age group for which some ATVs are r...

60 Driver Warnings WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climb- ing a hill. WHAT CAN HAPPEN: The ATV could overturn and cause injury. HOW TO AVOID THE HAZARD: Maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight up...

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

67 Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle r...

68 Features and Controls Engine Stop Switch The engine will not start or run when the stop switch is down, in the OFF position. Its pur- pose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the engine stop ...

69 Features and Controls Horn Button Use the horn for emergencies and to let others know you’re near. Engine Start Button The start button is located slightly above the choke lever1. Attach the tether strap securely to the vehicle and to the rider's right wrist.2. Shift the transmission to neutral. ...

70 Features and Controls Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for servic...

71 Features and Controls Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released.This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a froze...

72 Features and Controls Shift Lever To change gears, stop the ATV. With the engine idling, move the lever to the desired gear. Do not try to shift gears with engine speed above idle or while the ATV is mov- ing.Maintaining shift linkage adjustment is important to assure proper transmission function...

74 Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes. WARNING Applying only one brake could cause loss of control and result in serious injury or death. ...

75 Features and Controls Brakes Parking Brake 1. Squeeze the left brake lever.2. Push the parking brake lock down to lock the brake lever in place. 3. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. WARNING Operating the ATV while...

77 Features and Controls Lights Indicator Lights Indicator lights on the ATV let you know when your ATV is in neutral or reverse. WARNING Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced sp...

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

80 Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane of 87. Refer to the specifications sec- tion beginning on page 178 for fuel tank capacity. Gas Cap

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

82 Features and Controls Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced.1. Position the vehicle on a level surface.2. Shift the transmission to neutral.3. Lock the parking brake.4. Fold out the kick-sta...

83 Break-in Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment...

84 Break-in Period 1. Fill the fuel tank with gasoline. See page 78.2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 125. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and...

89 Starting the Engine 1. Shift the transmission to neutral.2. Lock the parking brake.3. Turn the fuel valve on.4. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist. NOTE: The choke is fully on when the lever is pushed completely to the left. The choke is off when the...

90 Starting the Engine 8. Squeeze the rear brake lever and press the starter button. NOTE: The rear brake lever must be engaged or the engine won't start. 9. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn't start, release the starter, wai...

91 Stopping the Engine 1. Release the throttle completely and brake to a complete stop.2. Shift the transmission to neutral.3. Stop the engine. NOTE: There are three ways to stop the engine. • Turn the key off.• Push the engine stop switch down.• Pull the tether strap off the ATV. NOTE: To avoid dra...

92 Driving Safely Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meet...

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

94 Driving Safely Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Shift the transmission to neutral.3. Start the engine and allow it to warm up.4. Check your surroundings and determine your path of travel. 5. Squeeze the left brake lever.6. Shift...

95 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 t...

96 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...

97 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, sharp tu...

98 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,...

99 Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (15 ° maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and...

100 Driving Safely Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner's manual.

101 Driving Safely Driving Across Hillsides 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 uphil...

102 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. Shift ...

103 Driving Safely Turning Around on a Hill 5. Staying uphill of the ATV, turn the handle- bars full left. 6. While holding the brake, release the park- ing 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...

104 Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Drive directly downhill.2. Transfer your weight to the rear of the vehicle. 3. Slow down.4. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing. WARNING Excessive speed can ...

105 Driving Safely Parking on a Hill or Incline Avoid parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions:1. Turn the engine off.2. Lock the parking brake.3. Always block the rear wheels on the downhill side as shown in the illus- tration. 4. Turn the fuel valve...

106 Driving Safely Driving Through Water Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests. Follow these procedures when operating through water:1. Determine water depths before driving through water. 2. If crossing a s...

108 Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the ter- rain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hang- ing branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not a...

109 Driving Safely Driving in Reverse Follow these guidelines when operating in reverse:1. Back slowly.2. Apply the brakes lightly for stopping.3. Avoid turning at sharp angles.4. Always avoid backing downhill.5. Never open the throttle suddenly while backing.6. Always look left, right and behind th...

110 Driving Safely Hauling Cargo The Sportsman 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling cargo on the following pages. Never carry cargo on the Outlaw 90. • Place 1/3 of the cargo weight on the front rack and 2/3 on the rear rack. Carrying l...

111 Driving Safely Hauling Cargo • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifica- tions section beginning on page 178. • Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or a tipover. Use suitable tie-downs...

112 Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require- ments. Operation on Public Lands in the U.S.A. Your Polaris vehi...

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

114 Maintenance Periodic Maintenance Chart To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat.Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour....

115 Maintenance Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you're not familiar with s...

116 Maintenance Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often under severe use, such as in dirty or wet condi- tions, to purge water or dirt contamination from grease fittings and other critical components. E Emission-related service (Failure to conduct this ...

122 Maintenance Lubrication Guide X Perform these procedures more often for vehicles subjected to severe use Item Lube Method Engine Oil Polaris Synthetic Youth Oil or Synthetic SAE 40 See page 124. Gearcase (Transmission) Oil Level Premium AGL Synthetic Gearcase Lube See page 130. Drive Chain Polar...

123 Maintenance Lubrication Guide Grease Points Grease Points

124 Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 182 for the part numbers...

125 Maintenance Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill.1. Position the vehicle on a level surface.2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely.4. Remove the dipstick and check the oil level. NOTE:...

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

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

129 Maintenance Fuel Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. Do not attempt to clean the fuel filter.

130 Maintenance Transmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of the ATV. Maintain the oil level at the bottom of the fill plug hole threads. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning...

131 Maintenance Transmission Oil Change 1. Position the vehicle on a level surface. 2. Remove the fill plug.3. Place a drain pan under the gearcase. 4. Remove the drain plug. Allow the oil to drain completely.5. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).6. Add the recommended...

132 Maintenance Spark Plugs Refer to the specifications section beginning on page 178 for spark plug and gap specifica- tions. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been drive...

133 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insul...

134 Maintenance Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service, or after 25 hours. Vehicle Immersion If 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 ver...

135 Maintenance Vehicle Immersion 5. Loosen the carburetor drain screw.6. Turn the engine over several times using the electric start.7. Dry the spark plug and reinstall it, or replace it with a new plug. 8. Tighten the carburetor drain screw.9. Turn the fuel valve on.10. Attempt to start the engine...

136 Maintenance Constant Variable Transmission (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system...

137 Maintenance CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bot- tom of the CVT cover.1. Remove the drain plug. Allow the water to drain. Reinstall the dr...

138 Maintenance Spark Arrestor To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. WARNING Failure to heed these warnings could result in serious injury or death.Do not perform service on the spark arrestor whil...

139 Maintenance Spark Arrestor 1. Remove the six bolts and remove the arres- tor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with com- pressed air. 3. Inspect the ...

140 Maintenance Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at alti- tudes 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 an...

142 Maintenance Speed Control System Per ANSI / SVIA-1-2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed of youth models is restricted to under 10 MPH for the 50cc models and under 15 MPH for the 90cc models. The dealer CANNOT, under any circumstances, either prior to the sale or later, even...

143 Maintenance Speed Control System Throttle Stop Speed Control System Use the following procedure to control how far the throttle opens.1. Loosen the jam nut.2. Turn the screw inward to reduce speed or outward to increase speed. 3. Tighten the jam nut after adjusting. Jam Nut Screw

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

145 Maintenance Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals rec- ommended in the Periodic Maintenance Chart beginning on page 114. If the freeplay isn’t at specification, adjust the freeplay as outlined on the following pages. Brake Freeplay Specificatio...

146 Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface.2. Shift the transmission to neutral.3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground. 4. While rotating the left front w...

147 Maintenance Brake Freeplay Front Brake Adjustment 6. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 7. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn. 8. Verify that the right-hand brake f...

148 Maintenance Brake Freeplay Rear Brake Adjustment 1. Position the vehicle on a level surface.2. Shift the transmission to neutral.3. Elevate the rear of the vehicle by placing a suitable stand under the frame. The rear tires should be slightly off the ground. 4. While rotating the rear wheels, ti...

149 Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. When freeplay specifications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine w...

150 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" (3-6 mm) toe out.1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether the handlebar...

151 Maintenance Toe Alignment 3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle. 4. Measure the distance from the string to the rim at the front and rear of...

152 Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The front and rear shock absorber sprin...

153 Maintenance Drive Chain Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the gen- eral lubrication interval specified in the Periodic Maintenance Chart beginning on page 114. Lubricate more often under severe use, such as in dirty or wet conditions. See page 1...

154 Maintenance Drive Chain Slack 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. Collapse the suspension with an adjustable (buckle type) trailer tie-down strap. Fasten the strap around the axle and rear bumper tube. 3. Tighte...

155 Maintenance Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts.2. Loosen the chain adjuster lock nut.3. Turn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). 5. Tighten the four rear housi...

156 Maintenance Air Filter 1. Remove the seat. See page 21.2. Release the air box cover spring clips and remove the cover.3. Remove the foam air filter. Wash the foam filter in warm soapy water, then rinse and let dry. If the filter is damaged, install a new foam filter. 4. Apply a commercially avai...

158 Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference.1. Remove the pod to access the handlebar bolts. Loosen the four bolts. 2. Adjust the handlebar to the desired height. Be sure the handlebars do not hit the gas tank or any other part of the vehicle when turned ...

159 Maintenance Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.Maintain proper tire pressure as described on the decal on your ...

160 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Wheel Removal 1. Stop the engine and lock the parking brake.2. Loosen the wheel bolts slightly.3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove...

161 Maintenance Wheel Installation 1. Lock the parking brake.2. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 3. Install the wheel bolts and finger tighten them.4. Lower the vehicl...

162 Maintenance Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized Polaris dealer. Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

163 Maintenance Tail Light Lamp Replacement If the brakelight doesn't work, the lamp may need to be replaced.1. Remove the two screws securing the lens cover. Remove the lens cover. 2. Remove the lamp and replace it with a new recommended lamp. 3. Test the light for proper operation.4. Reinstall the...

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

165 Maintenance Daytime Running Lights Lamp Replacement (if equipped) If the daytime running lights do not operate, replace the lamps. Polaris recommends that you install replacement lamps obtained from your authorized Polaris dealer.1. Remove the front cab (Outlaw only). 2. Disconnect the lights fr...

166 Maintenance Battery The battery in your Polaris ATV is a sealed battery. The sealing strip cannot be removed. Never add water to this type of battery.Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a ...

167 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.

168 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 ...

169 Maintenance Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, incl...

170 Maintenance Cleaning Washing the ATV The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently.3. Dry surfac...

172 Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehi- cle....

173 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 169. Battery Storage Remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recha...

174 Maintenance Storage Stabilize the Fuel Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes better starting after the storage period.1. Fill the fuel tank.2. Add Po...

176 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 114. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slig...

177 Maintenance Transporting the ATV Follow these procedures when transporting the ATV.1. Stop the engine.2. Place the transmission in gear.3. Lock the parking brake.4. Secure the fuel cap, oil cap and seat.5. Turn the fuel valve off.6. Always tie the frame of the ATV to the transporting unit secure...

178 Specifications Outlaw 90 Rider Capacity/Maximum Weight 1 Rider/170 lbs. (77 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication Wet Sump Oil Capacity 30 oz. (900 ml) Fuel Capacity 1.7 gallons (6.4 liters) Fuel Reserve Capacity .23 gallons (.86 liters) Starting Electric with...

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

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

184 Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Turn the fuel valve to reserve, refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fu...

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

186 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...

187 Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ...

188 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...

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

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

191 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 ...

193 Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND F...

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

195 Warranty EXPORTED VEHICLES How to Get Service I f You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be requi...

198 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 10 Hours (Break-in) 40 Hours 50...

202 Index A Accessories . . . . . . . . . . . . . . . . . . 177 Age Warning . . . . . . . . . . . . . . . . . 36 Air Filter . . . . . . . . . . . . . . . . 156-157 Axle and Wheel Nuts . . . . . . . . . . 162 B Battery Installation/Connections . . . 168 Removal . . . . . . . . . . . . . . . 167 Stora...