Polaris Sportsman 90 - User Manual

Polaris Sportsman 90

Polaris Sportsman 90 – User 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 6 – FOREWORD; and facilities to provide you with the best service possible.
  • Page 7 – PROTECT YOUR SPORT; Polaris Industries Inc.; having a similar function. Your model may differ.
  • Page 8 – INTRODUCTORY SAFETY MESSAGE TO PARENTS; AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE.; An ATV handles; SERIOUS INJURY or DEATH.; Never operate an ATV without proper instruction.; Take a training course.; Riders
  • Page 11 – straight down the hill where possible.
  • Page 12 – den throttle changes.
  • Page 14 – Indicates a potential hazard which could
  • Page 15 – TABLE OF CONTENTS
  • Page 17 – RIDER’S SECTION
  • Page 18 – KNOW YOUR MACHINE; Review the information in this manual with any child who may be
  • Page 19 – This is the safety alert symbol. When you see this symbol on your
  • Page 20 – Engine Stop Switch
  • Page 21 – Kick Starter; weak to start your machine, you can
  • Page 22 – Gas Cap; - This is where the gas goes
  • Page 23 – Brake Lever
  • Page 24 – Ignition Switch; - This key must be turned “on” before pushing the starter
  • Page 25 – always
  • Page 26 – Let’s review the three ways to stop your ATV.
  • Page 28 – PRE RIDE CHECK; for the first time, you must do a
  • Page 30 – Children
  • Page 31 – certain that; ALL THREE WAYS TO STOP; your ATV are working the way they
  • Page 32 – RIDING RULES; while you ride is the most important thing. Let’s learn how to ride!
  • Page 34 – help. Always drive within the sight of an adult.
  • Page 35 – could even die. All ice can be dangerous!
  • Page 36 – Only ride your ATV where you know it is safe to drive. No driving over
  • Page 37 – UNDERSTANDING WARNINGS; OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNER’S MANUAL; KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!; fore they first use the ATV and periodically afterwards.; SAFETY TRAINING
  • Page 38 – severe INJURY
  • Page 39 – the following messages:; This is the safety alert symbol. When you see this symbol on
  • Page 40 – Indicates a potential hazard which may re-; NOTE; The word “NOTE:” in this manual will alert you to
  • Page 41 – GENERAL SAFETY AND DESCRIPTION OF LABELS; ber is printed on the decal.
  • Page 43 – Improper ATV use can result in SEVERE INJURY OR DEATH.; WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEAL-
  • Page 45 – Kids under age 6 should NEVER operate this ATV. Kids under 6 have an
  • Page 46 – (Found on Scrambler 90 and Sportsman 90
  • Page 48 – IMPROPER TIRE PRESSURE OR
  • Page 51 – ATTENTION
  • Page 55 – POTENTIAL HAZARD
  • Page 56 – DAILY PRE-RIDE INSPECTION; Item/Inspection Procedure
  • Page 57 – secured by cotter pins; Indicates a potential hazard which could result in
  • Page 58 – OPERATION WARNINGS
  • Page 59 – the operator to shift position as needed during op-
  • Page 60 – surfaces may seriously affect handling and control of
  • Page 65 – Don’t try to show off.
  • Page 66 – described in the Owner’s Manual.
  • Page 67 – your ATV during operation.
  • Page 69 – which could result in an accident, including an
  • Page 72 – as described in the Owner’s Manual. See page 94.
  • Page 73 – Shift your weight to the uphill side of the ATV.
  • Page 75 – reduce the chance of skidding or sliding out of control.; Indicates a potential hazard which could result
  • Page 78 – WHAT CAN HAPPEN
  • Page 81 – sult in severe injury or death.; Indicates a potential hazard which could re-
  • Page 82 – authorized Polaris ATV dealer.
  • Page 83 – VEHICLE IDENTIFICATION NUMBERS
  • Page 84 – Frame VIN (found on the front of frame below steering post)
  • Page 85 – CONTROL AND PARTS FUNCTIONS; Engine Electrical Switches; the pod of the
  • Page 86 – - Emergency Engine Stop Switch
  • Page 87 – - Engine Start Button
  • Page 88 – CAUTION
  • Page 89 – Engine Throttle; gine and occasionally during riding.
  • Page 90 – Throttle Lever
  • Page 92 – Switches; or headlight pod and operated with a key.; Indicator Lights; this red dot is lit, it is indicating a low oil level.
  • Page 93 – Front and Rear Brakes; squeeze the left hand lever to-
  • Page 94 – Parking Brake; vent the lever from returning to the released
  • Page 95 – release automatically.; Important Safeguards; park brake before starting the engine.
  • Page 97 – The engine exhaust from this prod-
  • Page 98 – PVT System; responsibilities to make sure this system remains safe:
  • Page 99 – Engine Fuel and Oil System; The fuel tank filler cap (1) is located directly
  • Page 101 – annually. Do not attempt to clean the fuel filter.
  • Page 102 – Oil System
  • Page 103 – Polaris 2-Cycle Lubricants; laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.
  • Page 104 – gine damage may occur.
  • Page 106 – STARTING THE ENGINE; Procedure for Starting a Cold Engine; gine damage could result.
  • Page 107 – Attach tether strap to machine and wrist.
  • Page 108 – RIDING GEAR; Safe Riding Gear
  • Page 110 – VEHICLE BREAK-IN PERIOD; the fuel tank as outlined on page 65.
  • Page 111 – ize yourself with vehicle operation and handling.
  • Page 112 – brication without the need for pre-mixed fuel.
  • Page 113 – CARRYING LOADS; and never attempt to carry cargo on the Scrambler models.
  • Page 114 – follow the warnings listed below:
  • Page 116 – EXTREME CAUTION MUST BE USED when operating with loads ex-
  • Page 120 – RIDING
  • Page 121 – is controlled by the amount of throttle opening.
  • Page 122 – Making Turns
  • Page 123 – Practice making turns at slow speeds.
  • Page 124 – Riding On Slippery Surfaces
  • Page 125 – which can cause skids.
  • Page 126 – Traveling Uphill
  • Page 127 – If you have to travel uphill always travel straight uphill and:; dismounting of the ATV.
  • Page 128 – Sidehilling
  • Page 129 – into a situation where sidehilling is unavoidable, always:; on the uphill side
  • Page 130 – Traveling Downhill
  • Page 131 – control and tipping, resulting in severe injury or death.
  • Page 132 – Turning Around On A Hill
  • Page 133 – the service brake, until ATV is on reasonably level ground.
  • Page 134 – Crossing Streams
  • Page 135 – Before fording streams always:; sudden throttle changes.; critical; the machine is serviced as out-
  • Page 136 – Trail Obstacles
  • Page 138 – Parking on an Incline
  • Page 139 – Whenever the Vehicle is Parked; the rear wheels on the down hill side as shown on the facing page.
  • Page 140 – PVT SYSTEM OPERATION; lowing responsibilities to make sure this system remains safe:
  • Page 141 – Remove the screws and the crankcase cover.
  • Page 142 – BATTERY; Battery; Only adults should ever touch the battery.; Never allow children; to handle a; plosive situation could result causing serious injury or death.
  • Page 143 – Flush with water for 15 minutes and get prompt medical attention.
  • Page 144 – Replenishing the Battery Fluid; A poorly maintained battery will deteriorate rapidly.
  • Page 145 – Battery Removal; baking soda and one cup water to prevent damage to the ATV.
  • Page 146 – Battery Installation and Connections; exploding battery can cause serious injury or death.
  • Page 148 – NOISE EMISSION CONTROL SYSTEM REGULATION; LOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING:
  • Page 149 – Removal or alteration or the puncturing of any part
  • Page 150 – USFS Approved Spark Arrestor; the USFS Forest Service Standard 5100-1A.
  • Page 151 – MAINTENANCE; Tool Kits; ment under the seat. Items included in the kits are:; Periodic Maintenance Schedule; are explained in the following chart on the following pages.
  • Page 152 – Due to the nature of the adjustments marked with a
  • Page 153 – More often under severe use, such as dirty or wet conditions
  • Page 158 – Lubrication Recommendations; Item
  • Page 159 – Operating
  • Page 160 – More often under severe use, such as wet or dusty conditions.
  • Page 161 – Hours are based on 10 mph average.
  • Page 162 – Periodic Maintenance Record; Use the following chart to record periodic maintenance work:
  • Page 164 – Handlebar Adjustment
  • Page 166 – loosened for maintenance service.; Axle and Wheel Nut Torque Specifications; Specification; rized Polaris Dealer.; Front Wheel Hub Tightening
  • Page 167 – Rear Spring Adjustment
  • Page 168 – Air Cleaner; in wet or dusty conditions, clean the filter more often.
  • Page 169 – Remove the screws on
  • Page 170 – Throttle Stop System; The throttle stop system controls how
  • Page 171 – Exhaust System Restrictor; and
  • Page 172 – Spark Arrestor Restrictor
  • Page 173 – Steering Inspection; The camber and caster are non-adjustable.
  • Page 174 – Toe Alignment
  • Page 176 – Brake Adjustment; Periodically check the freeplay of the front
  • Page 177 – To adjust the rear brake, turn the adjuster nut
  • Page 178 – Brake Freeplay Adjustment; Model
  • Page 179 – Throttle Cable Adjustment; Always check the throttle for smooth
  • Page 180 – Spark Plugs; range for the engine and the service.
  • Page 181 – or incorrect carburetion adjustments.; Spark Plug Removal and Replacement; system or engine could burn you causing severe injury.
  • Page 182 – Storage; slow speed driving quality.
  • Page 183 – Cylinder Head/Cylinder Base Fastener Torque; torque at the first service or after 25 hours.
  • Page 184 – Transmission Lubrication
  • Page 185 – Transmission Oil Changing Procedure
  • Page 186 – an accident resulting in serious injury or death.
  • Page 187 – may affect ATV maneuverability.; Wheel Removal Procedure; Remove the wheel nuts and remove the wheel.
  • Page 188 – Tire Size
  • Page 189 – Wheel Installation; point toward forward rotation.
  • Page 190 – Tire Inspection; When replacing a tire always use original equip-; Tire Tread Depth; Always replace tires when tread depth is worn to
  • Page 191 – Drive Chain Inspection and Adjustment
  • Page 193 – Rear Drive Chain Slack Adjustment; The normal
  • Page 194 – Adjustment Procedure; Tighten the four rear housing mount bolts.
  • Page 195 – Brakelight Lamp Replacement; If the brakelight does not work the lamp may need to
  • Page 196 – Cleaning Your ATV; much like an automobile.; Washing; engine or exhaust system.
  • Page 197 – If warning labels are damaged, contact your a Polaris; Waxing; of harsh cleaners since they can scratch the body finish.
  • Page 198 – Transporting
  • Page 199 – Carburetor Adjustments; allow efficient operation. These changes include:
  • Page 200 – SPECIFICATIONS; Specifications - Scrambler 50
  • Page 202 – Specifications - Scrambler 90
  • Page 204 – Specifications - Sportsman 90
  • Page 206 – Low Oil Light; Accessories
  • Page 207 – WIRING DIAGRAM
  • Page 209 – TROUBLESHOOTING; Procedures
  • Page 211 – WARRANTY; LIMITED WARRANTY
  • Page 212 – REGISTRATION; SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE
  • Page 213 – WARRANTY COVERAGE AND EXCLUSIONS:; other cause beyond Polaris’ control.
  • Page 215 – HOW TO OBTAIN WARRANTY SERVICE
  • Page 216 – which vary from state to state.
  • Page 217 – INDEX
  • Page 220 – Improper ATV use can result in SEVERE INJURY or DEATH
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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 6 - FOREWORD; and facilities to provide you with the best service possible.

iii FOREWORD Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATVs). It is designed to provide superior riding comfort, enjoy- ment, and safety. This manual is furnished to ensure that the operator and parents are aware of safe operating proc...

Page 7 - PROTECT YOUR SPORT; Polaris Industries Inc.; having a similar function. Your model may differ.

iv PROTECT YOUR SPORT Know all local, state/province riding laws;Respect your vehicle;Respect the environment; andYou will gain the respect of others.We also advise you to strictly follow the recommended maintenance program as out- lined. This preventive maintenance program is designed to ensure tha...

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