Polaris Predator 90 - Manual

Polaris Predator 90

Polaris Predator 90 – Manual, read for free online in PDF format. We hope this helps you resolve any issues you may have. If you have further questions, please contact us through the contact form.

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Table of Contents:

  • Page 2 – WARNING; The engine exhaust from this
  • Page 3 – We’ve created a web site just for YOU!; Technical tips
  • Page 5 – WELCOME; Polaris Recreational and Utility Vehicles; RANGER; Polaris Professional Series Workmobiles
  • Page 7 – TABLE OF CONTENTS
  • Page 8 – VEHICLE IDENTIFICATION NUMBERS; serial number (2) are important for model identification when
  • Page 9 – SAFETY; Operator Safety; vehicle handles differently than other vehicles, such as
  • Page 10 – The following signal words and symbols appear throughout this; CAUTION
  • Page 11 – Take a training; Serious injury or death can result if you do not follow these
  • Page 13 – FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications
  • Page 14 – does not know how to operate the ATV properly in different
  • Page 15 – balance and control the ATV, which could cause an accident
  • Page 16 – surfaces may seriously affect the handling and control of the
  • Page 17 – including dirt and gravel roads. In many states it’s illegal to
  • Page 18 – risk of a severe head injury or death in the event of an
  • Page 19 – operator judgment. Reaction time may be slower and operator
  • Page 21 – schedules described in the owner’s manual.
  • Page 22 – terrain. Always be alert to changing terrain conditions.
  • Page 23 – cause loss of traction or loss of control, which could result in an
  • Page 24 – abilities. Never operate the ATV on hills steeper than 25
  • Page 25 – sharp drop, or another vehicle or person could be on the other
  • Page 26 – described in the owner’s manual.
  • Page 27 – mastered the turning technique (on level ground) as described in
  • Page 28 – improperly dismounting while
  • Page 29 – trees when possible. If unavoidable, use extreme caution and
  • Page 32 – confident that the ice is thick enough and sound enough to
  • Page 34 – Safety Decals and Locations; Warning decals have been placed on the ATV for your protection.; Trail Blazer models; Drum shift models
  • Page 35 – See your Owner’s Manual Supplement for specifications.
  • Page 36 – ATTENTION; Under Seat; NO STEP; On models with racks
  • Page 37 – Your ATV will not have all of the decals shown on this page.
  • Page 38 – Safe Riding Gear
  • Page 39 – CONTROLS; Electrical Switches; the override switch while the throttle is open.; Leaving the keys in the ignition can lead to unauthorized use of
  • Page 40 – Throttle Lever
  • Page 41 – Light Switches; designed for and must be used for; After opening a bottle of brake fluid, always discard any unused
  • Page 42 – Brake Lever; Operating the ATV with a spongy brake lever can result in
  • Page 43 – Parking Brake; Setting the Parking Brake; Important Safeguards; Operating the ATV while the parking brake is engaged could
  • Page 44 – Auxiliary Brake; reduce; Aggressively applying the rear brake when backing down a hill may
  • Page 45 – Choke
  • Page 46 – Fuel Safety
  • Page 47 – Models with 2-cycle engines have; Mixing brands or using a non-recommended oil may cause serious
  • Page 48 – Automatic Transmission Gear Selector; is located on the right side of the; Belt Life; Shifting gears with the engine speed above idle or while the
  • Page 49 – Recoil Starter; Extending the starter rope too far will cause damage to the recoil
  • Page 50 – FEATURES; Engaging Wheel Hubs; Switching to AWD while the rear wheels are spinning may cause
  • Page 51 – Disengaging Wheel Hubs; to one side, it’s likely that one front hub is engaged . If both hubs are; Operating with only one front hub engaged could result in loss of
  • Page 52 – Indicator Lights
  • Page 53 – Instrument Cluster; speed from the right front wheel. The instrument cluster measures; Washing the ATV with a high pressure washer may cause water to
  • Page 54 – Rider Information Center
  • Page 55 – mode
  • Page 56 – Mode 4 - Programmable Service Interval; OFF
  • Page 57 – Diagnostic Mode
  • Page 58 – OPERATION; The first tank of fuel must be pre-mixed according to the following; high speeds for extended periods during the first three hours of
  • Page 60 – working condition before each use.; Item/Inspection Procedure; that axle nuts are secured by cotter pins.; If a proper inspection is not done before each use, severe injury or
  • Page 61 – Starting the Engine; Starting a Cold Engine; Engine exhaust contains poisonous carbon monoxide and can; damage. Allow the engine to warm up for several minutes before
  • Page 62 – Starting a Warm Engine
  • Page 63 – Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Maximum Towing Capacities; Refer to your owner’s manual supplement for model specific towing; Use low forward gear when hauling or towing heavy cargo to extend
  • Page 65 – Driving Safely; Driving Procedures; Sit upright with both feet on the footrests and both hands on the
  • Page 66 – Making Turns; Some Polaris ATVs are equipped with a solid rear axle, which drives; overturn and lead to serious injury. Avoid turning at sharp angles.
  • Page 67 – Driving on Slippery Surfaces; quick, sharp turns which can cause skids.; Severe damage to drive train may occur if the AWD is engaged; Failure to exercise care when operating on slippery surfaces can
  • Page 68 – Driving Uphill; If all forward speed is lost:; terrain. Improper procedure could cause loss of control or
  • Page 69 – Sidehilling; while keeping your feet on the footrests.; as outlined in the owner’s manual.
  • Page 70 – Driving Downhill; slightly; Excessive speed can cause loss of control and lead to serious
  • Page 71 – Turning Around on a Hill; slowly; Improper hill climbing procedures could cause loss of control or
  • Page 72 – Driving Through Water; critical; Major engine damage can result if the vehicle is not thoroughly
  • Page 73 – Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
  • Page 74 – Driving in Reverse; lightly; Failure to use caution when operating in reverse can result in
  • Page 75 – Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
  • Page 76 – USFS Approved Spark Arrestor; Exhaust system components are very hot during and after use of
  • Page 77 – MAINTENANCE AND LUBRICATION; Accessories; Maintenance Chart Key
  • Page 78 – Periodic Maintenance Schedule; Hours of operation are based on a 10 mph average. If service is due at; Improperly performing the procedures marked with a
  • Page 82 – Lubrication Recommendations
  • Page 85 – position
  • Page 86 – Periodic Maintenance Record; Use the following chart to record periodic maintenance.
  • Page 87 – Polaris 2-Cycle Lubricants; Premium Gold Synthetic 2-Cycle Oil
  • Page 88 – Premium 4 Synthetic Oil; -Cycle Engines With External Oil Tank
  • Page 89 – Oil and Filter Change; Contact with hot oil may result in serious burns. Do not allow hot
  • Page 90 – Loss of oil pump prime could result in engine damage. It’s extremely
  • Page 92 – Polaris Premium 4 synthetic oil.
  • Page 93 – Transmission Oil Check - Models with Fill Plug; The transmission fill plug is located; Gearcase Oil Fill Chart
  • Page 94 – Transmission Oil Change - Models with Fill Plug; vehicle to access the fill plug.
  • Page 95 – Transmission Oil Check - Models with Dipstick
  • Page 96 – Transmission Oil Change - 2x4 Models
  • Page 97 – Front Gearcase Oil Check; Type A and B; Front Gearcase Oil Change; Gearcase
  • Page 98 – Rear Gearcase Oil Check
  • Page 99 – Counter Balance Oil Check - 400 2-Cycle Engines; Drain Locations
  • Page 100 – Engine Oil Check; The dipstick must be
  • Page 101 – Engine Cooling System; Coolant Level; GEN III
  • Page 102 – Radiator Coolant Level; Gen III; Escaping steam can cause severe burns. Never remove the
  • Page 103 – in loss of oil, which will cause serious engine damage. Always
  • Page 104 – Adjustments; Oil Pump - 250 Engines
  • Page 105 – Oil Pump - 400 Engines
  • Page 106 – Front Brake
  • Page 107 – Rear Brake
  • Page 108 – Toe Alignment; Severe injury or death can result from improper toe alignment and
  • Page 109 – Steering Assembly; dealer for service before operating the vehicle.; Camber and Caster; The camber and caster are non-adjustable.; Rear Spring; Accessory springs are available through your Polaris dealer.
  • Page 110 – Handlebars; Improper adjustment of the handlebars or incorrect torquing of
  • Page 111 – Carburetor
  • Page 113 – Side Panel Removal - Gen IV
  • Page 114 – Wheel Removal; Stop the engine, place the transmission in gear and lock the; Operating your ATV with worn tires, improperly inflated tires,
  • Page 115 – Wheel Installation; Bolt Size
  • Page 116 – Front Wheel Hub Tightening; component operations. All service must be performed by your; Tire Tread Depth; Always replace tires when tread; skidding, which could lead to loss of control and serious injury or
  • Page 117 – Drive Chain; Regularly lubricate the drive chain with SAE 80-90 lube or an; Washing the drive chain with a high pressure washer or
  • Page 118 – Rear Drive Chain Slack - Concentric Drive Models; this point the chain should have 3/16; Adjusting or operating the ATV with improper rear drive chain
  • Page 120 – Filter Systems; Air Filter Removal and Service - 2-Cycle Engines; Never
  • Page 121 – Operation of your vehicle without a breather filter can cause
  • Page 122 – Lights; Headlight Lamp Replacement - Scrambler; Poor lighting while driving can result in severe injury or death.
  • Page 123 – Headlight Lamp Replacement - Trail Blazer
  • Page 124 – Headlight Lamp Replacement - Gen IV; through the two small openings at the front of the headlight pod.
  • Page 125 – High Beam Adjustment - Gen IV
  • Page 126 – Headlight Housing Replacement - Gen IV
  • Page 127 – Taillight/Brakelight Lamp Replacement
  • Page 128 – Spark Plugs; Spark Plug Removal and Replacement; Using non-recommended spark plugs can result in serious engine; A hot exhaust system and engine can cause serious burns. Wear
  • Page 129 – Vehicle Immersion; If your vehicle becomes immersed, major engine damage can
  • Page 130 – Spark Arrestor; Failure to heed the following warnings while servicing the spark
  • Page 132 – Recoil Housing; must be behind the heat shield
  • Page 133 – PVT System; When To Use Low Range vs. High Range; Low Range
  • Page 134 – PVT Drying
  • Page 135 – Keep the battery terminals and connections free of corrosion. If
  • Page 136 – Battery; Replenishing Battery Fluid (Conventional Battery); in an explosion and cause serious injury or death. When removing; tablespoon baking soda and one cup water to prevent damage to
  • Page 137 – Battery Installation; fully charged
  • Page 138 – charged battery will register 12.8 V or higher.; An overheated battery could explode, causing severe injury or
  • Page 139 – Cleaning and Storage; Cleaning the ATV; damage plastic surfaces. Use caution when using these products
  • Page 140 – Storage Tips; Clean the Exterior; film created by fogging and damage could occur. Never start the
  • Page 141 – Fog the Engine
  • Page 142 – Battery Storage; Do not use tap water; Transporting the ATV
  • Page 143 – POLARIS RECOMMENDED PRODUCTS
  • Page 144 – TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause
  • Page 145 – solutions using the following charts.; Engine Doesn’t Turn Over
  • Page 146 – Engine Backfires
  • Page 147 – Engine Stops or Loses Power
  • Page 148 – WARRANTY; LIMITED WARRANTY
  • Page 150 – HOW TO OBTAIN WARRANTY SERVICE; Engine Oil
  • Page 151 – INDEX
  • Page 153 – PRINTED IN THE USA
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2003

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Summary

Page 2 - WARNING; The engine exhaust from this

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 3 - We’ve created a web site just for YOU!; Technical tips

1 We’ve created a web site just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.com/owner

Page 5 - WELCOME; Polaris Recreational and Utility Vehicles; RANGER; Polaris Professional Series Workmobiles

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S Victor...

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