Polaris Offroad Vehicle 419C User Manual

Pantone 419C

Owner's Manual for Maintenance and Safety

OUTLAW 90

SPORTSMAN 90

Read this manual carefully. It contains important safety information.

Adult supervision is required at all times.

Operation is prohibited for anyone under age 10.

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WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

A card containing important ATV safety information should be attached to the

owner's manual on the next page. If you cannot locate this card, or if it has been

removed, please call 1-800-342-3764 for assistance.

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Visit us at www.polaris.com

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POLARIS®, SPORTSMAN® and OUTLAW® are registered trademarks of POLARIS Industries Inc.

product information at the time of publication. Due to constant improvements in the design and quality of

production components, some minor discrepancies may result between the actual vehicle and the information

presented in this publication. Depictions and/or procedures in this publication are intended for reference use only.

No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or

procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the

original instructions.

Printed in Taiwan

2014 OUTLAW 90/SPORTSMAN 90 Owner's Manual

P/N 9924620

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Welcome

Dear Parents:

We believe your children should have the opportunity to enjoy the POLARIS riding

experience along with you. We've provided this owner's manual to assist you and your

children in learning about safe operation and care of your new ATV.

A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will

operate the ATV takes a training course before operating the ATV. Make sure all operators

understand and follow all of the instructions and warnings contained in this owner’s manual.

Never allow a child under the age of 16 to operate an ATV without adult supervision.

Children differ in skills, physical abilities and judgement. Some children may not be able to

operate an ATV safely. Permit continued use only if you determine that your child has the

ability and maturity to operate the ATV safely.

For your child’s safety, be sure your child can reach and operate all ATV controls, including

handlebars, brake levers, throttle lever and engine stop switch.

The preventive maintenance program outlined in this manual is designed to ensure that all

critical components on your child's ATV are thoroughly inspected at specific intervals.

Follow all of the instructions and recommendations in this manual.

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Welcome

Dear Children:

Before you ride your new POLARIS ATV, there are some important things that you

need to know. You must learn how to keep yourself and those around you safe while

you're riding. Your parents and Polaris want you to enjoy riding your new ATV, and

that's why you need to read and understand the information in your owner's manual.

You must also take an ATV training course before you begin riding.

Ask your parents to explain anything you don't understand, and pay close attention to

the warnings and instructions you read. Your safety and the safety of others is the

most important thing to think about at all times. Never drive your ATV alone.

Always make sure an adult is watching you when you ride.

Drive safely and enjoy riding your new POLARIS ATV!

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Table of Contents

Introduction. . . . . . . . . . . . . . . . . 6

Safety. . . . . . . . . . . . . . . . . . . . . . 8

Youth Section . . . . . . . . . . . . . . 39

Know Your ATV . . . . . . . . . . . 40

Pre-Ride Check. . . . . . . . . . . 47

Riding Rules . . . . . . . . . . . . . 50

Adult Section. . . . . . . . . . . . . . . 55

Vehicle ID Numbers. . . . . . . . 56

Features and Controls. . . . . . 57

Operation. . . . . . . . . . . . . . . . 69

Emission Control Systems. . . 96

Maintenance . . . . . . . . . . . . . 98

Specifications. . . . . . . . . . . . 162

POLARIS Products . . . . . . . 168

Troubleshooting. . . . . . . . . . 170

Warranty . . . . . . . . . . . . . . . 176

Maintenance Log. . . . . . . . . 191

Index. . . . . . . . . . . . . . . . . . . . . 195

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Introduction

Safety Words and Symbols

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.

CAUTION

A CAUTION indicates a hazardous situation

The safety alert symbol indicates a potential

which, if not avoided, could result in minor or

personal injury hazard.

moderate injury.

DANGER

NOTICE

A DANGER indicates a hazardous situation that,

A NOTICE indicates a situation that could result

if not avoided, will result in death or serious

in property damage.

injury.

WARNING

The Prohibition Safety Sign indicates

an action NOT to take in order to avoid

a hazard.

A WARNING indicates a hazardous situation

which, if not avoided, could result in death or

serious injury.

The Mandatory Action Sign indicates

an action that NEEDS to be taken to

avoid a hazard.

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Introduction

WARNING

Failure to follow the warnings and safety precautions contained in this manual can result in severe

injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles

differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly,

even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take

proper precautions.

• Read this owner’s manual. Understand all

safety warnings, precautions and operating

procedures before operating a POLARIS ATV.

Keep this manual with the ATV.

• Never operate an ATV without proper

instruction. Take a training course.

• For your child’s safety, be sure your child can

reach and operate all ATV controls, including

handlebars, brake levers, throttle lever and

engine stop switch.

• Always follow the age guidelines for your

vehicle. Y-10+ 90cc models are designed for

children not less than 10 years of age and

Y-6+ 50cc models are designed for children

not less than 6 years of age. No child under

the age of 16 should ride any ATV designed

and sold for an adult.

• Never permit a guest to operate the ATV

unless the guest has read this manual and all

product labels and has completed a certified

safety training course.

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Safety

Safety Training

ATV safety training is a top priority for

POLARIS. POLARIS strongly encourages

you and any family members who will be

riding the ATV to take a training course.

In addition, you were provided with printed

material and a video or DVD that instructs

operators on safe operating procedures. You

should review this information with your

child on a regular basis. Do not allow other

children to ride this ATV unless they have

read the manual, seen the instructional

video or DVD and taken and completed an

approved ATV safety training course.

If you purchased a new POLARIS ATV in

the United States, your dealer provided

information about the authorized ATV

RiderCourse that is available to you and

your eligible family members. This training

is included in the purchase price of your

ATV.

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Safety

Safety Training

FOR MORE INFORMATION ABOUT ATV

SAFETY in the United States, call the

Consumer Product Safety Commission

at 1-800-638-2772, or visit www.cpsc.gov,

visit www.atvsafety.org, or call POLARIS

at 1-800-342-3764.

If you purchased a used POLARIS ATV in

the United States, you can enroll in the ATV

RiderCourse for a fee. Call ATV

Enrollment Express at (800) 887-2887 or

visit www.atvsafety.org.

If you purchased a POLARIS ATV outside

the United States, please contact your dealer

or local law enforcement agencies for infor-

mation about safety training.

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Safety

Riding Gear

Long

Sleeves

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 meets or exceeds established safety stan-

dards.

Approved helmets in the USA and Canada bear a U.S.

Department of Transportation (DOT) label.

Eye

Protection

Gloves

Long Pants

Approved helmets in Europe, Asia and Oceania bear the

ECE 22.05 label. The ECE mark consists of a circle

surrounding the letter E, followed by the distinguishing

number of the country which has granted approval. The

approval number and serial number will also be

displayed on the label.

Boots

051039

0006.31

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Safety

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

markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of strong over-the-ankle boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with

kneepads and a jersey with shoulder pads provide the best protection.

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Safety

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used as directed.

WARNING! Modifying this vehicle in any way can change the top speed, stability and handling

performance of this vehicle. Modifications that increase speed, decrease stability or change

performance may present a greater risk to inexperienced or younger operators and could result in loss

of control and serious injury or death. Use only POLARIS-approved accessories to modify this vehicle.

Review all vehicle changes with your child prior to operating.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved equipment

and/or modifications have been added to the vehicle that increase speed or power.

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Safety

Safety Warnings

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which

may result in serious injury or death.

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 hazards

outlined in this section of the owner’s manual MUST be avoided at all times. See the RIDING RULES

section and the OPERATION section of the owner’s manual for proper operating procedures.

Operator Restrictions/Age Restrictions

This vehicle is for recreational use by young operators under

adult supervision ONLY.

Operation is prohibited for anyone under age 10.

UNDER

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Safety

Safety Warnings

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an

accident. The operator must understand how to operate the ATV

properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete an ATV

training course. They should then regularly practice the skills learned

in the course and the operating techniques described in the Owner's

Manual. See page 8.

Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified

safety training course.

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Safety

Safety Warnings

Handling Gasoline

Exposure to Exhaust

Gasoline is highly flammable and explosive

Engine exhaust fumes are poisonous and can

cause loss of consciousness or death in a short

time. Never start the engine or let it run in an

enclosed area.

under certain conditions.

• Never allow a child to refuel or handle

gasoline.

The engine exhaust from this product contains

chemicals known to cause cancer, birth defects

or other reproductive harm. Operate this vehicle

only outdoors or in well-ventilated areas.

• 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 sparks

in or near the area where refueling is

performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank

neck.

• If gasoline spills on your skin or clothing,

immediately wash it off with soap and water

and change clothing.

• Turn the fuel valve off whenever the ATV is

stored or parked. See page 67.

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Safety

Safety Warnings

Failure to Inspect Before Operating

Protective Apparel

Failure to inspect and verify that the ATV is in

safe operating condition before operating

increases the risk of an accident. Always inspect

the ATV before each use to make sure it's in safe

operating condition. Always follow all inspection

and maintenance procedures and schedules

described in the owner's manual.

Operating this ATV

without wearing an

approved helmet

increases the risk of

a serious head

injury in the event of

an accident.

Operating without

eye protection could

result in an accident

and could increase

the chance of a

serious injury in the

event of an accident.

Always wear an approved helmet that fits

properly. Always wear eye protection (goggles or

face shield), gloves, boots, a long-sleeved shirt

or jacket and long pants.

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Safety

Safety Warnings

Carrying a Passenger

Using Alcohol or Drugs

Carrying a passenger greatly reduces the

operator's ability to balance and control the ATV,

which may result in an accident or overturn.

Never carry a passenger on this ATV.

Operating the ATV after consuming alcohol or

drugs could adversely affect operator judgment,

reaction time, balance and perception. Never

consume alcohol or drugs before or while

operating an ATV.

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Safety

Safety Warnings

Operating on Pavement

Operating on Public Roads

Operating an ATV on paved surfaces (including

sidewalks, paths, parking lots and driveways)

may adversely affect the handling of the ATV and

could result in loss of control and accident or

overturn. Avoid operating the ATV on pavement.

ATV tires are designed for off-road use. If it's

unavoidable, travel slowly and avoid sudden

turns or stops.

Operating this ATV on public streets, roads or

highways could result in a collision with another

vehicle. Never operate the ATV on any public

street, road or highway, including dirt and gravel

roads. In many states it's unlawful to operate

ATVs on public streets, roads and highways.

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Safety

Safety Warnings

Operating at Excessive Speeds

Physical Control of the ATV

Operating the ATV at excessive speeds

increases the operator's risk of losing control.

Always operate at a speed that's appropriate for

the terrain, the visibility and operating conditions,

and your experience.

Removing a hand from the handlebars or feet

from the footrests during operation can reduce

your ability to control the vehicle or cause loss of

balance and ejection from the ATV. If the

operator's foot is not firmly planted on the

footrest, it could also contact the rear wheels.

Never remove your hands from the handlebars

while operating, and always keep both feet on

the footrests.

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Safety

Safety Warnings

Turning Improperly

Jumps and Stunts

Turning improperly could cause loss of traction,

loss of control, accident or overturn. Always

follow proper procedures for turning as described

in the owner's manual.

Attempting wheelies, jumps and other stunts

increases the risk of an accident or overturn.

Never attempt wheelies, jumps, or other stunts.

Avoid exhibition driving.

Never turn abruptly or at sharp angles. Never

turn at high speeds. Practice turning at slow

speeds before attempting to turn at faster

speeds.

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Safety

Safety Warnings

Improper Hill Climbing

Operating on Steep Hills

Improper hill climbing could cause loss of control

or overturn. Always follow proper procedures for

climbing hills as described in the owner's

manual. See page 84.

Operating on excessively steep hills could cause

an overturn. Never operate on hills too steep for

the ATV or for your abilities. Never operate the

ATV on hills steeper than 15 degrees.

>15°

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Safety

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

• Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE:

A special technique is required when braking while traveling downhill. See page 87.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.

Travel straight down the hill when possible.

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Safety

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure

could cause loss of control or overturn. Avoid crossing the

side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper

procedures as described in the owner's manual. See page 86.

Never attempt to turn the ATV around on any hill until you've

mastered the turning technique (on level ground) as

described in the owner's manual. See page 88.

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Safety

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while

climbing a hill could cause an overturn.

Always maintain a steady speed when climbing a hill.

If all forward speed is lost

If you lose all forward speed: Keep your weight uphill. Apply the

front brakes gradually (right lever). When fully stopped, apply the

rear brake as well (left lever) and then lock the parking brake.

If the ATV begins rolling downhill: Keep weight uphill. Never apply

engine power. Never apply the rear brake while rolling

backwards. Apply the front brake slowly. When fully stopped,

apply rear brake as well, and then lock the parking brake.

Dismount on uphill side, or to either side if pointed straight uphill.

Turn the ATV around and remount, following the procedure

described in the Owner's Manual. See page 88.

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Safety

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively

rough, slippery or loose terrain could cause loss of traction,

loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose terrain

until you've learned and practiced the skills necessary to

control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

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Safety

Safety Warnings

Operating in Unfamiliar Terrain

Improper Tire Maintenance

Failure to use extra caution when operating on

unfamiliar terrain could result in an accident or

overturn. Unfamiliar terrain may contain hidden

rocks, bumps, or holes that could cause loss of

control or overturn.

Travel slowly and use extra caution when

operating on unfamiliar terrain. Always be alert to

changing terrain conditions.

Operating this ATV with improper tires or with

improper or uneven tire pressure could cause

loss of control or accident.

Always use the size and type of tires specified for

your ATV. Always maintain proper tire pressure

as described in the owner's manual and on

safety labels.

Operating Improperly in Reverse

Improperly operating in reverse could result in a

collision with an obstacle or person. Always

follow proper operating procedures as outlined in

this manual. See page 81.

Before shifting into reverse gear, always check

for obstacles or people behind the ATV. When it's

safe to proceed, back slowly.

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Safety

Safety Warnings

Improper Vehicle Modifications

Operating Over Obstacles

Improper installation of accessories or

modification of the ATV may cause changes in

handling, which could cause loss of control or an

accident.

Never modify the ATV through improper

installation or use of accessories. All parts and

accessories added to the vehicle must be

genuine POLARIS Industries Inc. or equivalent

components designed for use on this ATV and

should be installed and used according to

approved instructions. See your authorized

POLARIS ATV dealer for more information.

Improperly operating over obstacles could cause

loss of control or overturn.

Before operating in a new area, check for

obstacles. Avoid operating over large obstacles

such as rocks and fallen trees. If unavoidable,

use extreme caution and always follow proper

operating procedures as outlined in this manual.

Skidding or Sliding

Skidding or sliding can cause loss of control or

overturn (if tires regain traction unexpectedly).

On slippery surfaces such as ice, travel slowly

and use extra caution to reduce the chance of

skidding or sliding.

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Safety

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of

control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water

that exceeds the height of the footrests:

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make

sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them

lightly several times while driving. The friction will help dry out the pads.

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Safety

Safety Warnings

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo may cause

changes in handling, which could cause loss of control or

an accident. Never haul cargo or tow a load with this ATV.

Never tow or pull an object behind the ATV. A wagon, sled

or other towed object does not have brakes or steering.

The object may overturn or collide with other objects.

Never exceed the stated load capacity for this ATV.

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Safety

Safety Warnings

Operating on Frozen Bodies of Water

Physical Skills

Operating on frozen bodies of water may result in

serious injury or death if the ATV and/or the

operator fall through the ice. Never operate the

ATV on a frozen body of water.

Safe operation of this rider-active vehicle

requires good judgement and physical skills.

Persons with cognitive or physical disabilities

who operate this vehicle have an increased risk

of overturn and loss of control.

Operating a Damaged ATV

Hot Exhaust Systems

Operating a damaged ATV can result in an

accident. After any overturn or accident, have a

qualified service dealer inspect the entire

machine for possible damage, including (but not

limited to) brakes, throttle and steering systems.

Exhaust system components are very hot during

and after use of the vehicle. Hot components can

cause burns and fire. Do not touch hot exhaust

system components. Always keep combustible

materials away from the exhaust system.

Use caution when traveling through tall grass,

especially dry grass. Always inspect the

underside of the ATV after driving through tall

grass, weeds, brush and other tall ground cover.

Promptly remove any grass or debris clinging to

the vehicle.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to

unauthorized use of the vehicle, which could

result in an accident or overturn. Always remove

the ignition key when the vehicle is not in use.

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Safety

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery

is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

•

Instrument and calibration uncertainty

Variations in the machine such as wear of components

Variation of machine operators such as experience or physique

Ability of the worker to reproduce typical work during measurements

Environmental factors such as ambient noise or temperature

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Safety

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the

instructions on each label carefully. If any of the labels shown in this manual differ from the

labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS

dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no

charge. The part number is printed on the label.

Age Warning

WARNING

Operation of this ATV by children under age 10 increases the

risk of severe injury or death.

Adult supervision required for children under age 16.

NEVER permit children under age 10 to operate this ATV.

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Safety

Safety Labels and Locations

Operation Warning

WARNING

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 conditions; on public roads

- a collision can occur with another vehicle; with a passenger -

passengers affect balance and steering and increase risk of

losing control.

ALWAYS: use proper riding techniques to avoid vehicle

overturns on hills and rough terrain and in turns; avoid paved

surfaces - pavement may seriously affect handling and control.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL

INSTRUCTIONS AND WARNINGS.

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Safety

Safety Labels and Locations

Discretionary Warning

WARNING

Never operate this ATV on HILLS steeper than

15 degrees

15°. To prevent overturn on hilly

terrain, use throttle and brakes gradually and shift

weight uphill.

REVERSE operation can be dangerous even at

low speeds. Steering becomes difficult. To

prevent loss of control, avoid sudden braking or

sharp turns.

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Safety

Safety Labels and Locations

Tire Pressure Warning (OUTLAW 90)

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa)

• Maximum Weight Capacity 180 lbs. (81.7 kg)

Tire Pressure Warning (SPORTSMAN 90)

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa)

• Maximum Weight Capacity 225 lbs. (102 kg)

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Safety

Safety Labels and Locations

No Passenger Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in

SEVERE INJURY or DEATH.

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Safety

Safety Labels and Locations

SPORTSMAN 90 Rack Warning

WARNING

• DO NOT TOW. Vehicle damage or tipover may

result causing severe injury or death.

• Maximum Rack Loads:

Front 15 lbs. (7 kg)

Rear 30 lbs. (14 kg)

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Safety

Safety Labels and Locations

Clutch Cover Warning

WARNING

NO STEP

• Moving parts hazard under belt-clutch guard. To pre-

vent 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, and excessive

engine RPM which can result in serious injury or

death.

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Youth

Section

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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 126.

These units are not designed for adult use. Serious damage to the vehicle may occur if the

maximum rider weight capacity is exceeded. See the specifications section beginning on

page 162 for your ATV's capacity.

CHILDREN: Before you ride your new POLARIS ATV, there are some important things

that you need to know. Your safety and the safety of others is the most important thing to

think about at all times. As the driver of the ATV, you must learn how to keep yourself and

those around you safe while you're riding.

Pay attention when you see this symbol:

This is the safety alert symbol. When you see this symbol on your ATV or in this manual it

means PAY ATTENTION because you could die or be seriously injured if you don't follow the

instructions.

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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 again.

2. Horn Button - Press the horn button to sound the horn.

3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to

go forward. Always make sure the throttle control does not stick before you drive your

ATV. Read more about it on page 47.

2. Horn Button

1. Engine Stop Switch

3. Throttle Control

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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 68.

5. Shift Lever

5. Shift Lever - The shift lever is on the

right side of your ATV. Read about how

to use the shift lever on page 62.

4. Kick-Start Lever

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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.

6. Gas Cap

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. Reach under the

left rear fender and pull back on the

latch to remove the seat. To replace the

seat, set it in place and push down on

the seat above the latch. Always make

sure the seat is locked in place before

riding.

7. Seat Latch

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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 could lose control of the ATV and

be seriously injured. Always take your thumb off the throttle lever when you squeeze the

brake levers.

8. Front Brakes

8. Rear Brakes

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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. If you fall off your ATV, the tether strap

will pull away from the switch and the engine will stop.

9. Ignition Switch

10. Tether Switch

9. Ignition Switch

10. Tether Switch

OUTLAW

SPORTSMAN

Never ride without the tether strap attached to your right wrist and to your ATV. Be careful not

to let the cord get tangled around the handlebars or any part of your body.

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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.

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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 now.

1. Make sure the throttle doesn't stick. Check this by pushing the throttle lever toward the

handlebar and then letting go. The lever should come right back to where it was before

you pushed it. If it comes back slowly or stays close to the handlebar, the ATV has a

sticky throttle. This means that something is wrong or broken and must be fixed before

you can ride your ATV safely.

Never start the engine if you have a sticky throttle. You could be seriously hurt if you ride with

a sticky throttle. Have an adult or your POLARIS dealer fix the throttle before you ride.

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Pre-Ride Check

2. 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 fixed before you can ride your ATV safely.

Never start the engine if your ATV has sticky brakes. You could be seriously hurt if you ride

with sticky brakes. Have an adult or your POLARIS dealer fix the sticky brakes before you

ride.

3. Have an adult check to see if your ATV needs more gas. Children must never add their

own gasoline. This must always be done by an adult. Before anyone adds gasoline to

your ATV they must read the instructions and warnings on page 15 of this manual.

Always have an adult put gas in your ATV. Never try to do it yourself.

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Pre-Ride Check

4. If you used the storage area under the seat, make sure the seat is locked in place.

5. Have an adult check the engine oil level when the engine is cold. The engine is very hot

after it has been running and it can burn your skin if you touch it. Children must never

check the oil on their own. An adult should always be in charge of keeping the gas and

oil levels at the full marks.

6. This last check is done with the engine running. You must check to make sure that all

three ways to stop the engine of your ATV are working the way they should. Do you

remember what they are? If you can't remember the three ways to stop the engine, go

back to page 46 and review. Then have an adult help you start the engine. Practice stop-

ping the engine all three ways.

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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 driv-

ing an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.

ŹThe adult with you is your teacher. Always pay attention to what your teacher says so you

can learn how to always drive safely.

Let's learn how to ride!

Always follow the safe riding rules found on the next pages. You or others around you could

be seriously hurt if you don't follow the safe riding rules.

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Riding Rules

ŹAlways wear the right kind of clothing and safety gear

when riding your ATV.

Long

Sleeves

Helmet

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

can see where you're driving.

Gloves: Wear gloves to protect your hands from sun and

wind. Gloves will also protect your hands from scrapes

and scratches.

Eye

Protection

Gloves

Long Pants

Boots: Wear sturdy over-the-ankle boots to keep your

feet dry. Boots will also protect your feet and ankles from

scrapes and scratches.

Boots

Clothing: Make sure your clothing fits properly. If it's

too small, it could keep you from moving easily when

you shift your weight. If it's too big, it could hang down and get caught in a moving part.

Wear long sleeves and long pants to protect your arms and legs.

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Riding Rules

ŹAlways attach the tether strap to your right wrist

and to the ATV before riding.

ŹMake sure you know where you're going to drive

before your ATV is started. Make sure the area is

safe all around your ATV.

ŹYour ATV is made for one person. Never carry a

passenger. A passenger will make the ATV harder

to drive. You may lose control and hurt yourself

and your passenger.

ŹAlways drive your ATV while sitting down. Keep

both hands on the handlebars and keep both feet on

the footrests.

ŹAlways be alert and pay attention to where you're driving. Pay attention to other drivers,

and be even more careful around them because you don't know what they're going to do.

ŹNever follow another ATV too closely. You need lots of time and space to stop your ATV.

ŹNever tow or pull an object behind the ATV.

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Riding Rules

ŹNever ride alone. An adult should always be watching you in case you need help. Always

drive within the sight of an adult.

ŹNever ride on public trails.

ŹDon'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.

ŹDon't ride at night. Your ATV doesn't have lights that are safe for driving in the dark.

ŹLearn where there are lakes, rivers, ponds and ditches in your driving area. Stay away

from them.

ŹNever ride on frozen water. You could get hurt or you could even die. All ice can be dan-

gerous!

ŹRide your ATV only where you know it is safe to drive and where you have permission to

drive. Be careful of the things around you.

ŹAlways be a polite driver. (Don’t drive through the flower garden or over the little trees

you planted!)

ŹAlways do your best to help take care of nature.

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Respect your ATV;

respect your environment;

and you will earn

the respect of everyone.

Enjoy riding your new POLARIS ATV!

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Adult

Section

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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 existing keys.

The ignition switch must be replaced if

all keys are lost.

Engine Serial Number

VIN

Vehicle Model Number: ____________________________________________________________________

Frame VIN:______________________________________________________________________________

Engine Serial Number:_____________________________________________________________________

Key Number (on the key): __________________________________________________________________

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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. Always

remove the ignition key when the vehicle is not in use.

Key

OUTLAW

SPORTSMAN

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Features and Controls

Engine Stop Switch

Horn

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.

Both the main switch and the engine stop

switch shut off all electrical power to the

entire vehicle. To stop the engine quickly,

push the stop switch down.

Start Button

Choke Lever

Use the choke to start a cold engine. Push the choke lever to the left before starting the

engine. When the engine starts, gradually return the choke lever to the OFF position as the

engine warms up and runs smoothly.

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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 lever.

Follow the Starting the Engine procedure beginning on page 76.

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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 service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throt-

tle lever sticks during operation. Always check the lever for free movement and return before starting

the engine. Also check occasionally during operation.

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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 frozen or stuck throttle. If the throttle

cable should stick in an open position when the

operator releases the throttle lever, the engine will

stop and power to the rear wheels will cease.

Throttle

Lever

WARNING! The Electronic Throttle Control (ETC) stops

the engine in the event of a throttle system malfunction. Modifications to the electronic throttle control

could result in failure to perform as designed, which could result in an accident. Do not attempt to

modify the ETC system or replace it with any after market throttle mechanism. Always ensure that the

throttle cable is installed and properly routed to the throttle control.

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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 moving.

Maintaining shift linkage adjustment is important

to assure proper transmission function. See your

dealer if you experience any shifting problems.

Shift

Lever

Shift Pattern

F: Forward Gear

N: Neutral

R: Reverse

NOTICE: Do not attempt to shift the transmission

while the vehicle is moving or damage to

the transmission could result. Always shift

when the vehicle is stationary and the

engine is at idle.

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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.

Always apply both brakes at the same time.

Front Brakes

Rear Brakes

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Features and Controls

Brakes

Parking Brake

Not Locked

1. Squeeze the left brake lever.

Locked

2. Push the parking brake lock down to lock

the brake lever in place.

3. Release the brake lever.

4. To release the parking brake lock,

squeeze and release the brake lever. The

parking brake will release automatically.

5. Always lock the parking brake whenever the vehicle is left unattended.

WARNING! Operating the ATV while the parking brake is engaged could cause an accident resulting in

serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage

the parking brake before operating the ATV.

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Features and Controls

Lights

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 speeds in conditions of reduced visibility.

This ATV is designed for off-road use only. Do not operate this ATV on streets or highways.

Indicator Lights

Indicator lights on the ATV let

Neutral

you know when your ATV is in

neutral or reverse.

Reverse

Neutral

Reverse

OUTLAW

SPORTSMAN

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Features and Controls

Fuel System

Gas Cap

The fuel tank filler cap is located directly below the

handlebars.

Use POLARIS Carbon Clean fuel treatment at each

fill. Follow the mixing directions on the container.

See page 168 for the part numbers of POLARIS

products.

Use unleaded gasoline with a minimum pump

octane number of 87=(R+ M/2) octane. Non-

ethanol fuel is recommended. Do not use fuel with

ethanol content greater than 10 percent, such as E-85 fuel.

Refer to the specifications section beginning on page 162 for fuel tank capacity.

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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.

SPORTSMAN 90

Fuel Valve

ON: For normal operation.

RES: For reserve supply if main supply

is exhausted.

The reserve setting allows operation for

approximately 7-10 miles (11-16 km).

Always refill the gas tank as soon as

possible after using the main supply.

Always return the valve to the ON posi-

tion after refueling.

OUTLAW 90

Fuel Valve

OFF

RES

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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-start lever on the left side of the ATV.

Tip: A 10/12mm wrench is provided in the tool kit for removing or

installing the lever. If not installed, make sure the rubber cap is

on the kick-start shaft to protect the rider. Store the lever under

the seat when it’s not installed.

5. Turn the fuel valve on.

6. Push the engine stop switch up to the ON position.

7. Turn the key to ON.

Kick-Start Lever

8. Place your foot on the kick-start, then thrust your heel

downward to crank the engine.

9. After the engine has started, fold the kick-start lever back into place.

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Operation

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which

may result in serious injury or death. Read and understand all safety warnings outlined in the safety

section of this owner’s manual.

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

of a new engine will result in more efficient performance and longer life for the engine. Per-

form the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts. Do not operate at full throttle or high speeds for extended periods during the

first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

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Operation

Break-in Period

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling

gasoline. See page 15.

2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the

proper range. See page 109.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with

operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

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Operation

Break-in Period

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride

inspection checklist. See page 72.

6. Perform the following maintenance at the end of the break-in period.

See

Page

Item

End of Break-In Remarks

Engine oil change

Oil pre-filter screen

Transmission oil

Valve clearance

Perform break-in oil change

110

111

114

Clean filter with oil change

Perform break-in oil change

See your dealer for inspection and adjustment

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Operation

Pre-Ride Inspection

Failure to inspect and verify that the ATV is in safe operating condition before operating

increases the risk of an accident. Always inspect the ATV before each use to make sure it's in

safe operating condition.

Pre-Ride Checklist

Item

Remarks

Ensure proper operation

Page

Brake system / lever travel

Front suspension

Rear suspension

Steering

129, 133

106

Inspect, lubricate if necessary

106

Ensure free operation, lubricate if necessary

Check condition and pressure

134, 136

143

Tires

Wheels / fasteners

Inspect, ensure fastener tightness; check that

axle nuts are secured by cotter pins

145, 146

Fuel and oil

Check and fill as needed

15, 66

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Operation

Pre-Ride Inspection

Pre-Ride Checklist

Item

Remarks

Page

Throttle

Check for proper operation

Check for proper function

Check for proper operation

Inspect, clean or replace

47, 60, 61

Engine stop switch

Daytime running lights (if equipped)

Brakelight

149

147

Air filter, pre-filter

Drive chain

140

Check condition and slack; refer to drive

chain adjustment

137

Frame nuts, bolts, fasteners

Inspect, ensure tightness

Loose or damaged components

Visually inspect for any damaged compo-

nents or loose fasteners

Riding gear

Wear helmet, goggles, protective clothing

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Operation

Safe Operation Practices

1. Complete the recommended safety

training before operating this vehicle.

See page 8.

2. Do not allow anyone under age 10 to

operate this vehicle.

5. Operate this vehicle off-road only.

Never operate the vehicle on pavement

or on any public street, road or highway,

including dirt and gravel roads.

6. Never exceed the maximum weight

capacity of the vehicle. When determin-

ing the weight you are adding to the

vehicle, include the weight of the opera-

tor, accessories and loads on the racks

(if equipped). The combined weight of

these items must not exceed the maxi-

mum weight capacity.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous.

Never start the engine or let it run in an

enclosed area.

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Operation

Safe Operation Practices

7. Drive in a manner appropriate for your

skills and operating conditions. Never

operate at excessive speeds. Never

attempt wheelies, jumps, or other stunts.

Never remove your hands from the han-

dlebars while operating, and always

keep both feet on the footrests.

8. Never consume alcohol or drugs before

or while operating an ATV.

9. Always use the size and type of tires

specified for your vehicle. Always

maintain proper tire pressure.

10. Never operate a damaged ATV. After

any overturn or accident, have a quali-

fied service dealer inspect the entire

machine for possible damage.

11. Never operate the ATV on a frozen

body of water.

12. Do not touch hot exhaust system com-

ponents. Always keep combustible

materials away from the exhaust sys-

tem.

13. Always remove the ignition key when

the vehicle is not in use to prevent unau-

thorized use.

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Operation

Starting the Engine

NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine

to warm up for several minutes before operating.

1. Shift the transmission to neutral.

2. Lock the parking brake.

3. Turn the fuel valve on.

4. Sit on the vehicle. Attach the tether strap to

the ATV and to your wrist.

Choke Off

5. If the engine is cold, use full choke by

pushing the choke lever all the way to the

left. A warm engine will not require the use

of the choke.

Full Choke

Tip: The choke is fully on when the lever is pushed completely to the left. The choke is off when the

lever is pushed completely to the right. The choke can be adjusted gradually, depending on how

much choke is needed for starting.

6. Push the engine stop switch up to the ON position.

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Operation

Starting the Engine

7. Turn the ignition key to ON.

8. Squeeze the rear brake lever and press the starter button. The rear brake lever must be

engaged or the engine won't start.

9. Do not press the throttle while starting the engine. Activate the starter for a maximum of

five seconds, releasing the button when the engine starts. If it doesn't start, release the

starter, wait five seconds, then activate for another five seconds. Repeat until the engine

starts.

10. If the engine slows or stops, position the choke lever half way to allow proper engine

warm up. Vary the RPM slightly with the throttle to aid in warm up.

11. When the engine idles smoothly, push the choke lever all the way to the right.

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Operation

Stopping the Engine

1. Release the throttle completely.

2. Apply the brakes until the vehicle stops moving.

3. Shift the transmission to neutral.

4. Stop the engine. 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.

5. Lock the parking brake.

6. To avoid draining the battery, always turn the key to the OFF position when the engine is

not running.

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Operation

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 the transmission to the desired gear.

7. Slowly release the brake lever.

8. Slowly press the throttle with your right thumb

and begin driving.

9. Drive slowly at first. Practice turning and using the throttle and brakes on level surfaces.

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Operation

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 turn, steer in the direction of the turn, leaning

your upper body to the inside of the turn while

supporting your weight on the outer footrest.

This technique alters the balance of traction

between the rear wheels, allowing the turn to be

made smoothly.

Practice making turns at slow speeds.

WARNING! Turning improperly can result in vehicle

overturn. Never turn abruptly or at sharp angles.

Never turn at high speeds.

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Operation

Driving in Reverse

Follow these precautions when operating in

reverse:

1. Always check for obstacles or people

behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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Operation

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such

as wet trails or loose gravel, or during

freezing weather, follow these precautions:

1. Do not operate on excessively rough,

slippery or loose terrain.

2. Slow down when entering slippery

areas.

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Operation

Driving on Slippery Surfaces

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns,

which can cause skids.

4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the

direction of the skid and shifting your body weight forward.

Sideways skid

Turn in direction of

skid

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Operation

Driving Uphill

Braking and handling are greatly affected when

operating in hilly terrain. Improper procedure

could cause loss of control or overturn. When-

ever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (15° maximum).

3. Always check the terrain carefully before

ascending any hill.

4. Never climb hills with excessively slippery

or loose surfaces.

15° Maximum

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Operation

Driving Uphill

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly

could cause the ATV to flip over backwards.

8. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another

vehicle or person could be on the other side of the hill.

9. Remain alert and be prepared to take emergency action. This may include quick dis-

mounting of the vehicle.

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Operation

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or

overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow

these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper

body weight uphill while keeping your feet

on the footrests.

3. If the vehicle begins to slide or tip, quickly

turn the front wheel downhill, if possible,

or dismount on the uphill side immediately!

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Operation

Driving Downhill

When driving downhill, follow these precau-

tions:

1. Avoid steep hills (15° maximum).

2. Shift body weight uphill. Transfer your

weight to the rear of the vehicle.

3. Drive straight downhill.

4. Slow down. Excessive speed when trav-

eling downhill can cause loss of control.

5. Apply the front and rear brakes at the

same time, and very slightly, to aid in

slowing.

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Operation

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn

around.

1. Stop the vehicle and lock the parking brake while keeping body weight uphill.

2. Shift the transmission to neutral.

3. Shut off the engine.

4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight

uphill.

5. Staying uphill of the ATV, turn the handlebars full left.

6. While holding the brake, release the parking brake lock and slowly release the brake,

allowing the ATV to roll around to your right until it's pointing across the hill or slightly

downward.

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Operation

Turning Around on a Hill

7. Lock the parking brake and remount the

ATV from the uphill side, keeping body

weight uphill.

8. Restart the engine.

9. Squeeze the rear brake lever.

10. Shift the transmission to forward gear.

11. Release the parking brake and drive slowly,

controlling speed with the rear brake, until

the ATV is on more level ground.

8 ft. (2.4 m)

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Operation

Parking on a Hill or Incline

Avoid parking on a hill or incline if pos-

sible. If it's unavoidable, follow these

precautions:

1. Stop the engine.

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 off.

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Operation

Driving Over Obstacles

Follow these precautions when operating over

obstacles:

1. Always check for obstacles before operat-

ing in a new area.

2. Look ahead and learn to read the terrain.

Be constantly alert for hazards such as

logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when

operating on unfamiliar terrain. Not all

obstacles are immediately visible.

4. Never attempt to operate over large obsta-

cles, such as rocks or fallen trees.

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Operation

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 precautions when operating through water:

1. Determine water depth and current before

entering water.

2. If crossing a stream, choose a crossing where

both banks have gradual inclines.

3. Avoid operating through deep or fast-flowing

water.

Maximum Depth

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Operation

Driving Through Water

4. After driving through water, dry the brakes by applying light pressure to the levers

(while moving) until braking action is normal. If you do not perform this procedure, your

brakes may be ineffective.

NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating

in water deeper than the footrest level. As soon as possible, perform the inspections and

maintenance services outlined in the periodic maintenance chart beginning on page 98.

Engine oil, gearcase oil, front and rear gearcases (if equipped) and all grease fittings need

special attention.

If the vehicle tips or overturns in water, or if the engine stops during or after operating in

water, restarting can result in serious engine damage. Transport the vehicle to your dealer

for service before restarting the engine. If this is not possible, follow the vehicle immersion

inspection and drying procedures outlined on page 118, then see your dealer for service at

the first opportunity.

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Operation

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 OUT-

LAW 90.

WARNING

Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of

control, which can result in serious injury or death. Always follow these precautions when hauling

cargo:

• Place 1/3 of the cargo weight on the front

rack and 2/3 on the rear rack. Carrying loads

on only one rack increases the chance of a

2/3

1/3

tipover.

• Slow down. Allow more space for stopping

the ATV when hauling cargo.

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Operation

Hauling Cargo

• Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section

beginning on page 162.

• Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or

a tipover. Use suitable tie-downs or rope to secure the cargo. Do not allow cargo or tie straps to hang

over the edges of the racks.

• Carry only small loads that fit on the racks. Tall loads raise the center of gravity of the vehicle and

may cause loss of control or a tipover.

• Never allow a person to ride on the racks.

• Never tow or pull an object behind the ATV. A wagon, sled or other object towed behind an ATV does

not have brakes or steering. The object may overturn or collide with other objects and cause serious

injuries.

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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 requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS stan-

dard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated

on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to

monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion cham-

ber by the intake system. All exhaust gases exit through the exhaust system.

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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 maintained at POLARIS specifications to achieve opti-

mal performance.

Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjust-

ments should be performed by an authorized POLARIS dealer.

The emissions label is located on the clutch cover or engine case near the clutch box.

The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all man-

ufacturer warranties and may violate laws governing the registration and operation of this vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active

implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of

their device and the applicable electromagnetic standards and directives that apply to this vehicle.

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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. Vehicles subjected to severe

use must be inspected and serviced more frequently. Record maintenance and service in the

Maintenance Log beginning on page 191.

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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.

Service and adjustments are critical. If you're not familiar with safe service and adjustment

procedures, have a qualified dealer perform these operations.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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Maintenance

Periodic Maintenance Chart

Maintenance Chart Key

Symbol

Description

Perform these operations more often for vehicles subjected to severe use, such as in dirty or

wet conditions, to purge water or dirt contamination from grease fittings and other critical com-

ponents.

Emission-related service (failure to conduct this maintenance will not void the emissions war-

ranty but may affect emissions)

Have an authorized POLARIS dealer perform these services.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and cause an accident, which may result in serious injury or death. Always have an authorized

POLARIS dealer perform these services.

100

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Miles (Km)

Steering

Daily

Check each day before operating

the vehicle. Make adjustments as

needed. See the Pre-Ride Check-

list.

Front suspension

Rear suspension

Tires

Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

Fuel Tank

Add Carbon Clean with each fuel

fill.

140

Air filter, pre-filter & main

element

Daily

Inspect; clean often; replace as

needed

Air box sediment tube

Daily

Drain deposits when visible

Daytime running lights/tail

lamp

Check operation; apply dielectric

grease if replacing

147

149

101

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Miles (Km)

Drive chain

Daily

Inspect daily; adjust and lubricate

if needed

137

121

CVT housing (if equipped)

Break-in Maintenance

Weekly

Drain water as needed, check

often if operating in wet conditions

After first 10 hours of operation Perform break-in maintenance

Brake lever travel/brake

freeplay

Monthly

100 (160)

Inspect regularly

129

133

Spark plug

Monthly

100 (160)

Clean; check condition; adjust

gap; replace as needed

116

Idle speed

Choke

Monthly

100 (160)

Check; adjust as needed

125

Check for proper operation; see

your dealer for adjustments

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized POLARIS dealer perform these services.

102

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Miles (Km)

Battery

Monthly

6 M

200 (320)

300 (480)

400 (640)

Check terminals; clean; test

Drain and change the oil

150

110

114

111

Engine oil change

Transmission oil

Oil pre-filter screen

12 M

Clean filter at every oil change;

clean annually if ATV is operated

less than 10 hours

General lubrication

Valve clearance

3 M

6 M

500 (800)

500 (800

500 (800)

Lubricate all fittings, pivots,

cables, etc.

Check clearance; see your dealer

for adjustments

Carburetor float bowl

Throttle cable/ETC switch

Choke cable

Drain bowl periodically and prior

to storage

Inspect; adjust; lubricate; replace

if necessary

Inspect; adjust; lubricate; replace

if necessary

103

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Miles (Km)

Carburetor air intake

ducts/flange

6 M

500 (800)

Check for proper sealing/air leaks

Drive belt

6 M

500 (800)

See your POLARIS dealer

Brake pad wear

Fuel system

Fuel filter

100

12 M

1000 (1600) Check for leaks at tank cap, lines,

fuel valve, filter, pump, carbure-

tor; replace lines every two years

1000 (1600) Change filter

113

Engine mounts

Exhaust muffler/pipe

Ignition timing

100

12 M

1000 (1600) Inspect

Perform these procedures more often for vehicles subjected to severe use.

Emission-Related Service

Have an authorized POLARIS dealer perform these services.

104

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Maintenance

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

See

Page

(whichever comes first)

Hours Calendar Miles (Km)

Wiring

100

12 M

1000 (1600) Inspect for wear, routing, security;

apply dielectric grease to connec-

tors subjected to water, mud, etc.

Clutches (drive and driven)

Front wheel bearings

Spark arrester

100

300

12 M

36 M

1000 (1600) Inspect; clean; replace worn parts

1000 (1600) Inspect; replace as needed

3000 (4800) Clean out

122

134

Toe adjustment

Inspect periodically; adjust when

parts are replaced

105

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Maintenance

Lubrication Guide

Item

Lube

Method

See page 108.

Engine Oil

PS-4 Extreme Duty

10W-50 4-Cycle Oil

Gearcase

AGL Gearcase Lubricant &

See page 114.

See page 137.

(Transmission) Oil Level Transmission Fluid

Drive Chain

POLARIS Chain Lube or SAE

80/90

Ź Front Suspension

(A-Arm)

POLARIS All Season Grease or Inspect; tighten fasteners;

grease conforming to NLGI No. 2 grease (also after washing

ATV or driving in water).

Perform these procedures more often for vehicles subjected to severe use.

106

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Maintenance

Lubrication Guide

Grease Points

107

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Maintenance

Engine Oil

Oil Recommendations

Always check and change the engine oil at the intervals outlined in the Periodic Maintenance

Chart beginning on page 98. POLARIS recommends the use of POLARIS PS-4 Extreme

Duty 4-Cycle engine oil for this vehicle. Oil may need to be changed more frequently if

POLARIS oil is not used. Do not use automotive oil. See page 168 for the part numbers of

POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always

use the recommended oil. Never substitute or mix oil brands.

108

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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.

Dipstick

Tip: A rising oil level between checks in cool weather

driving can indicate contaminants such as gas or

moisture collecting in the crankcase. If the oil level

is over the full/safe mark, change the oil immedi-

ately.

Safe Range

5. Add the recommended oil as needed.

6. Reinstall the dipstick.

Add Oil

Full

109

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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 burns to skin. Do not allow hot oil to contact skin.

110

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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 on the plug. The sealing surfaces on the plug and crankcase should be clean and

free of burrs, nicks or scratches.

9. Reassemble the pre-filter screen and spring to the pre-filter plug.

111

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Maintenance

Engine Oil Change

10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm).

11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. See

the specifications section beginning on page 162 for capacities.

12. Reinstall the dipstick.

13. Start the engine. Allow it to idle for one to two minutes.

14. Stop the engine and inspect for leaks.

15. Check the oil level. Add oil as needed to bring the level to the upper mark on the dip-

stick.

16. Dispose of used oil properly.

112

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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 98. Do not attempt to clean the fuel filter.

113

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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 on page 98. POLARIS recommends

the use of AGL Gearcase Lubricant & Transmis-

sion Fluid. See page 168 for the part numbers of

POLARIS products.

Fill Plug

Drain Plug

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. View the oil level through the fill hole.

4. If the level is low, add the recommended oil.

5. Reinstall the fill plug.

114

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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 oil. Maintain the oil level at the bottom of the fill plug hole

threads.

7. Reinstall the fill plug. Check for leaks.

8. Dispose of used oil properly.

Gearcase Capacity

OUTLAW 90

SPORTSMAN 90

11.8 oz. (350 ml)

115

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Maintenance

Spark Plugs

Refer to the specifications section beginning on page 162 for spark plug and gap specifica-

tions.

NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use

POLARIS-recommended spark plugs.

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 driven at higher

speeds. Immediately check the spark plug for correct color.

CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when

removing a spark plug for inspection.

116

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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. The tip should not be white. A white insulator tip indicates overheat-

ing, caused by use of an improper spark plug or incorrect fuel system operation.

Wet Fouled Plug

The wet fouled 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 of

fouling are excessive oil, use of non-recommended injection oil, improper use of the choke,

or incorrect fuel system operation.

Spark Plug Change

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclock-

wise to remove it.

3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).

117

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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 the vehicle tips or overturns in water deeper than the footrest level, or if the engine stops

during or after operating in water, restarting WILL result in serious engine damage. Trans-

port the vehicle to your dealer for service before restarting the engine. If this is not possible,

follow the vehicle immersion inspection and drying procedures outlined below. This proce-

dure will allow short-term operation only to drive the ATV to a trailer or towing vehicle.

1. Move the ATV to dry land or at the very least, to water below the footrests.

2. Turn the fuel valve off.

3. Check the air box for any water and dry it if water is present.

4. Remove the spark plug.

118

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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. If necessary, repeat the drying

procedure.

11. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

12. If water has been ingested into the transmission, follow the

procedure on page 121 for drying the CVT.

Drain Screw

119

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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 has been precision balanced. Any modification will cause

the system to be out of balance, creating vibration and additional loads on components.

The CVT system rotates at high speeds, creating large amounts of force on clutch components.

Extensive engineering and testing has been conducted to ensure the safety of this product. However,

as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's

manual.

• This CVT system is intended for use on POLARIS products only. Do not install it in any other prod-

uct.

• Always make sure the CVT housing is securely in place during operation.

120

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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 drain plug.

2. Shift the transmission to neutral.

3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-

dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

4. Allow the engine RPM to settle to idle speed.

5. Test for belt slippage. If the belt slips, repeat the process.

6. Take the vehicle to your dealer for service as soon as possible.

NOTICE: Exposure to salt water will cause corrosion to metal components. If your vehicle is operated

in salt water areas, rinse it off frequently with fresh water.

121

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Maintenance

Spark Arrester

To remove accumulated carbon, clean the spark arrester at the intervals recommended in the

Periodic Maintenance Chart beginning on page 98.

WARNING

Failure to heed these warnings could result in serious injury or death.

• Do not perform service on the spark arrester while the system is hot. Allow components to cool suffi-

ciently before proceeding.

• Wear eye protection and gloves.

• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.

122

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Maintenance

Spark Arrester

1. Remove the six bolts and remove the

arrester from the end of the muffler.

2. Use a non-synthetic brush to clean the

arrester screen. A synthetic brush may

melt if components are warm. If necessary,

blow debris from the screen with com-

pressed air.

3. Inspect the screen for wear and damage.

Replace the arrester if damage is found.

4. Reinstall the arrester.

5. Torque the bolts to 7 ft. lbs. (9.5 Nm).

Arrester Screen

123

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Maintenance

Carburetor

Your POLARIS ATV is calibrated at the factory for optimal performance at altitudes ranging

from zero to 8,000 feet (2400 m) and temperatures above 15° F (-9° C). Refer to the specifi-

cations section beginning on page 162 for carburetor and jetting specifications.

Any jetting changes must be made only by an authorized POLARIS dealer. Always see your

dealer if jetting changes are needed.

124

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Maintenance

Carburetor

If engine idle speed is too high the vehicle will creep. If idle speed is too low the engine will

stall. To adjust idle speed, do the following:

1. Lock the parking brake.

2. Start the engine.

3. Allow the engine to warm up for approximately five minutes.

4. Adjust the carburetor idle screw either in or out until the desired idle speed is reached.

Turning the screw in (clockwise) will increase idle speed. Turning the screw out (coun-

ter-clockwise) will decrease idle speed.

Tip: If using an RPM gauge, the factory idle speed setting for 90cc models is 1700 +/- 100 RPM.

125

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Maintenance

Speed Control System

Per ANSI / SVIA-1-2010 (sec. 6.2) AS DELIVERED TO THE CONSUMER, the speed of

youth models is restricted to 10 MPH or less for the 50cc Y-6+ models and 15 MPH or less

for the 90cc Y-10+ models.

The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the

consumer's request, remove or adjust any speed limiting devices.

Your POLARIS ATV has an adjustable throttle limiting screw. Speed limiting devices may

be adjusted/removed only by consumers when they determine that their child is capable of

handling the additional speed.

Per ANSI / SVIA-1-2010 (sec. 6.1) the unrestricted top speed is 15 MPH or less for the 50cc

Y-6+ models and 30 MPH or less for the 90cc Y-10+ models.

126

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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.

Jam Nut

Screw

2. Turn the screw inward to reduce speed or

outward to increase speed.

3. Tighten the jam nut after adjusting.

127

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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 acceptable limit.

Adjustment

Nut

1/16" - 1/8"

(1.5 - 3.2 mm)

128

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Maintenance

Brake Freeplay

Measure Freeplay

Check (measure) the freeplay of the

front and rear brakes at the intervals rec-

ommended in the Periodic Maintenance

Chart beginning on page 98. If the free-

play isn’t at specification, adjust the

freeplay as outlined on the following

pages.

Brake Freeplay Specifications

Model

Front Brake

Rear Brake

90cc Models

.08”-.12" (2-3 mm)

129

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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 wheel,

tighten the upper front brake adjuster

nut on the right-hand control.

Front Brake

Adjuster Nuts

5. When you begin to feel a slight drag

in wheel rotation, loosen the adjuster

nut one full turn.

130

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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 functions correctly.

9. Verify that brake lever freeplay is at specification. See page 129.

10. Carefully lower the vehicle to the ground.

131

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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, tighten the rear brake

wing nut at the rear brake drum.

5. When you begin to feel a slight drag in wheel rota-

tion, loosen the wing nut one full turn.

6. Verify that the left hand brake functions correctly.

7. Verify that brake lever freeplay is at specification.

See page 129.

Rear Brake

Wing Nut

8. Carefully lower the vehicle to the ground.

132

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Maintenance

Brake Lever Travel

Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart

beginning on page 98. When freeplay specifications can no longer be obtained through

adjustment as outlined on the preceding pages, use the following information to determine

when to service the brakes.

Service the brakes when brake

lever travel reaches the total lever

travel measurement listed in the

table below. Always service the

brakes when there is no longer

sufficient stopping ability at the

specified lever travel setting.

Measure

Lever

Travel

Component

Total Lever Travel

Front brake lever

Rear brake lever

1 3/4" (45 mm)

2 1/2" (65 mm)

133

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Maintenance

Toe Alignment

Use the following procedure to check the toe align-

ment of the vehicle. The recommended toe alignment

is 1/8" to 1/4" (3-6 mm) toe out.

WARNING! Severe injury or death can result from

improper toe alignment and adjustment. Do not attempt to

adjust tie rod alignment. All tie rod adjustments should be

performed by an authorized POLARIS dealer.

Stand

String

1. Position the vehicle on a level surface.

2. Place the handlebars in a straight-ahead position.

3. Tie a length of string between two stands as

shown in the illustration. Position the stands so

that the string is flush with the side of the rear

tire. If available, you may use a long straight-

edge instead of string.

134

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Maintenance

Toe Alignment

4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front

rim. The rear measurement should be 1/16"-1/8" (2-3 mm) more than the front measure-

ment on each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6 mm) toe

out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your POLARIS dealer for service.

135

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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 springs are adjustable

to increase or decrease spring tension. Rotate the

adjuster either clockwise or counter-clockwise to make

adjustments.

Adjuster

136

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Maintenance

Drive Chain

Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the

general lubrication interval specified in the Periodic Maintenance Chart beginning on page

98. Lubricate more often under severe use, such as in dirty or wet conditions. See page 168

for the part numbers of POLARIS products.

NOTICE: Washing the drive chain with a high pressure washer or gasoline can cause premature wear

and drive chain failure. Don't use a high pressure washer or gasoline to clean the drive

chain.

Adjusting or operating the ATV with improper rear drive chain slack can result in severe

damage to the transmission and drive components. Always make sure the slack is within the

stated specifications.

137

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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. Tighten the strap until a straight line

can be drawn from the rear axle to the

gearcase output shaft intersecting the

swing arm pivot. This establishes the

tightest chain position.

Strap

Chain

Tensioner

4. Pull down on the chain tensioner to

move it out of the way, then measure

chain slack. It should have 1/4"-1/2" (6-12 mm) deflection.

5. If the chain needs adjustment, use the procedure on page 139.

138

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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). Hold the adjuster stud securely while

tightening the nut to avoid breaking the stud.

5. Tighten the four rear housing mount bolts to 43

ft. lbs. (60 Nm).

Housing

Mount

Bolts

Chain Adjuster

139

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Maintenance

Air Filter

1. Remove the seat. See page 43.

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 available foam filter lubricant to the foam filter.

Clips

Cover

Foam Filter

Support Screen

140

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Maintenance

Air Filter

5. Clean away any oil or sediments in the air box.

6. Reinstall the filter and air box cover. Secure the clips.

7. Reinstall the seat.

NOTICE: Never operate the ATV with the filter element removed. Dirt will enter the engine causing

rapid wear and severe damage to the engine.

141

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Maintenance

Handlebar Adjustment

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can

cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious

personal injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for

service.

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 fully to the left or

right.

3. Lightly tighten each bolt equally to prevent uneven

gaps in the block. Torque the bolts to 7.3 ft. lbs. (10

Nm).

Bolts

142

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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. Always

follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle.

Always use original equipment size and type when replacing tires.

143

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Maintenance

Tire Tread Depth

Always replace tires when tread depth is

worn to 1/8" (3 mm) or less.

1/8" (3 mm)

Wheel Removal

1. Stop the engine and lock the parking brake.

2. Loosen the wheel bolts slightly.

Wheel

Bolts

3. Elevate the side of the vehicle by placing a

suitable stand under the footrest frame.

4. Remove the wheel bolts and remove the

wheel.

144

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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 vehicle to the ground.

5. Securely tighten the bolts to 22 ft. lbs. (30 Nm).

145

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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.

146

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Maintenance

Tail Light Lamp Replacement

Lamp

If the brakelight doesn't work, the lamp may

need to be replaced.

Cover

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.

Screws

3. Test the light for proper operation.

4. Reinstall the lens cover.

147

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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 new lamp.

6. Reverse the steps to reinstall all components.

148

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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 from the harness.

3. Remove the rubber cover from the back of the light assembly.

4. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note the posi-

tion of the lamp positioning tab, then carefully pull the lamp out.

5. Install the new lamp. Make sure the filament is horizontal.

6. Reinstall the lamp retainer. Press the retainer inward and turn it clockwise about 1/4 turn.

7. Start the engine to make sure the lights come on. If the lights do not operate, see your

POLARIS dealer for service.

8. Reinstall the rubber cover, and reconnect the lights to the harness.

9. Reinstall the front cab (OUTLAW only).

149

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Maintenance

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious

injury or death. When removing the battery, always disconnect the negative (black) cable first. When

reinstalling the battery, always connect the negative (black) cable last.

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 solution of one tablespoon baking

soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat

the terminals with dielectric grease or petroleum jelly to reduce oxidation and excessive

power consumption.

150

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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.

151

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Maintenance

Battery

Battery Installation and Connections

Always install a fully charged battery. Using a new battery that has not been fully charged

can damage the battery and result in a shorter life. It can also hinder vehicle performance. If

recharging is necessary, use a .5 amp battery charger

1. Set the battery in its holder.

2. Coat the terminals with dielectric grease or petroleum jelly.

3. Connect and tighten the red (positive) cable first.

4. Connect and tighten the black (negative) cable last.

5. Attach the hold-down strap.

6. Verify that cables are properly routed.

152

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Maintenance

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, 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 recharge as needed to maintain a full

charge.

Cleaning

Keeping your ATV clean will not only improve its appearance but it can also extend the life

of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle

by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle.

153

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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 surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

154

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Maintenance

Cleaning

Washing the ATV

If a high pressure water system is used for cleaning (not recommended), exercise extreme

caution. The water may damage components and could remove paint and decals. Avoid

directing the water stream at the following items:

• Wheel bearings

• Radiator

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

If warning and safety labels are damaged, contact your POLARIS dealer for free replace-

ment.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to

evaporate any water that may have entered the engine or exhaust system.

155

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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.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

156

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Maintenance

Storage

Exterior

Make necessary repairs and clean the vehicle as recommended. See page 153.

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 recharge as needed

to maintain a full charge.

157

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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 pro-

motes better starting after the storage period.

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer. Follow the

instructions on the container for the recommended amount. Carbon clean will also

reduce the possibility of bacterial growth in the fuel system.

3. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse

through the fuel in the tank and carburetor.

4. Stop the engine.

5. Turn the fuel valve off.

6. Drain the carburetor bowl.

158

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Maintenance

Storage

Engine Oil

Change the oil. See page 110.

Air Filter / Air Box

Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sedi-

ment tube.

Fluid Levels

Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart

beginning on page 98.

• Transmission Oil

• Engine Oil

• Brake Fluid

159

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Maintenance

Storage

Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-

tenance Chart beginning on page 98.

Storage Area/Covers

1. Make sure tire pressure is at specification.

2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not

touching the ground.

3. Be sure the storage area is well ventilated.

4. Cover the vehicle with an appropriate cover. Do not use plastic or coated materials. They

do not allow enough ventilation to prevent condensation, and may promote corrosion

and oxidation.

160

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Maintenance

Transporting the ATV

1. Stop the engine. Place the transmission in gear. Lock the parking brake.

2. Secure the fuel cap, oil cap and seat. Turn the fuel valve off.

NOTICE: Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope.

The rack, bumper or handlebars do not offer enough support for tie-down while transporting.

3. Wrap the front tie strap through the frame tubes (not through the bumper tubes), or attach

a tie-down hook around each of the tubes.

4. Wrap the rear tie strap around the grab bar.

Tubes

Step 3

Step 4

161

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Specifications

OUTLAW 90

Rider Capacity/Maximum Weight

Displacement

Cooling

1 Rider/180 lbs. (81.7 kg)

89cc

Air Cooled

Engine type

4-Stroke

Lubrication

Wet Sump

Oil Capacity

30 oz. (900 ml)

Fuel Capacity

Fuel Reserve Capacity

Starting

Drive System

Final Drive

1.7 gallons (6.4 liters)

.23 gallons (.86 liters)

Electric with kick-start backup

Automatic CVT

Chain

Front Suspension

Rear Suspension

Front/Rear Brakes

Parking Brake

Front Tires

Single A-arm with 5" (12.7 cm) of travel

Swing arm with 6" (15.2 cm) of travel

Drum

Mechanical Lock

19 x 7 - 8 (3 psi/20.7 kPa)

18 x 9.5 - 8 (3 psi/20.7 kPa)

Rear Tires

162

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Specifications

OUTLAW 90

Dry Weight

270 lbs. (122.4 kg)

Length/Width/Height

Wheel Base

61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm)

41.5" (105 cm)

Ground Clearance

Brake Light

Daytime Running Lights

4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame

Standard

Carburetor Settings

Cutaway

n/a

Pilot Air Screw

Needle Jet

Pilot Jet

1.25 turns out

Main Jet

E-Clip Position

#4 from top

163

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Specifications

OUTLAW 90 Carburetor Jetting

*Shaded cells indicate factory settings.

AMBIENT TEMPERATURE

ALTITUDE

°F:

°C:

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Below -25

Below-35

-30 to -10

-34 to -23

-15 to +5

-26 to -15

0 to +20

-18 to -7

+15 to +35 +30 to +50 +45 to +65 Above +60

-9 to +2

Meters (Feet)

-1 to +10

+7 to +18 Above +16

0-600

(0-2000)

600-1200

(2000-4000)

1200-1800

(4000-6000)

1800-2400

(6000-8000)

2400-3000

(8000-10000)

3000-3700

(10000-12000)

Clip Position

The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR 1051.115(d)(3).

164

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Specifications

SPORTSMAN 90

Rider Capacity/Maximum Weight

Displacement

1 Rider/180 lbs. (81.7 kg)

89cc

Cooling

Air Cooled

Engine type

4-Stroke

Lubrication

Wet Sump

Oil Capacity

Fuel Capacity

Fuel Reserve Capacity

Starting

Drive System

30 oz. (900 ml)

2 gallons (7.7 liters)

.22 gallons (.85 liters)

Electric with kick-start backup

Automatic CVT

Chain

Final Drive

Front Suspension

Rear Suspension

Front Rack Capacity

Rear Rack Capacity

Front/Rear Brakes

Parking Brake

Single A-arm with 5" (12.7 cm) of travel

Swing arm with 6" (15.2 cm) of travel

15 lbs. (7 kg)

30 lbs. (14 kg)

Drum

Mechanical Lock

165

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Specifications

SPORTSMAN 90

Front Tires

19 x 7 - 8 (3 psi/20.7 kPa)

Rear Tires

Dry Weight

18 x 9.5 - 8 (3 psi/20.7 kPa)

289 lbs. (131 kg)

Length/Width/Height

Wheel Base

61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm)

41.5" (105 cm)

Ground Clearance

Brake Light

4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame

Standard

Daytime Running Lights

Standard

Carburetor Settings

Cutaway

n/a

Pilot Air Screw

Needle Jet

Pilot Jet

1.25 turns out

Main Jet

E-Clip Position

#4 from top

166

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Specifications

SPORTSMAN 90 Carburetor Jetting

*Shaded cells indicate factory settings.

AMBIENT TEMPERATURE

ALTITUDE

°F:

°C:

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Clip Position

Main Jet

Pilot Jet

Below -25

Below-35

-30 to -10

-34 to -23

-15 to +5

-26 to -15

0 to +20

-18 to -7

+15 to +35 +30 to +50 +45 to +65 Above +60

-9 to +2

Meters (Feet)

-1 to +10

+7 to +18 Above +16

0-600

(0-2000)

600-1200

(2000-4000)

1200-1800

(4000-6000)

1800-2400

(6000-8000)

2400-3000

(8000-10000)

3000-3700

(10000-12000)

Clip Position

The carburetor jetting chart above is consistent with the provisions of U.S.A. federal regulation 40 CFR 1051.115(d)(3).

167

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POLARIS Products

Part Number

Description

Engine Lubricant

Fogging Oil (12 oz. Aerosol)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)

PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2870791

2878920

2878919

2878068

2878069

2872348

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l)

AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)

Chain Lube, Aerosol

168

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POLARIS Products

Part Number

Description

Grease

2871322

2871423

All Season Grease (3 oz./89 ml)

All Season Grease (14 oz./414 ml)

Miscellaneous Additives

2871326

Carbon Clean

169

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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

Inspect and clean or replace

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Overuse of choke

Drain the fuel system and refuel

Turn the fuel valve on

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your POLARIS dealer

Inspect, clean and/or replace spark plugs

Replace the filter

Clogged fuel filter

Low battery voltage

Recharge battery with .5 amp charger

See your POLARIS dealer

Mechanical failure

170

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Troubleshooting

Engine Doesn’t Turn Over

Possible Cause

Solution

Low battery voltage

Recharge battery with .5 amp charger

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your POLARIS dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

171

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Troubleshooting

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your POLARIS dealer

Mechanical failure

Exhaust system leak

172

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Inspect, clean and/or replace spark plugs

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

See your POLARIS dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery with .5 amp charger

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your POLARIS dealer

Clogged air filter

Electronic throttle control malfunction

Other mechanical failure

173

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Lean Fuel Mixture Cause

Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Possible Rich Fuel Mixture Cause

Solution

Overuse of choke

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

Fuel is very high octane

174

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Troubleshooting

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn the fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

See your POLARIS dealer

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery with .5 amp charger

Replace with recommended fuel

Inspect and clean or replace

Incorrect fuel

Clogged air filter

Electronic throttle control malfunction

Other mechanical failure

See your POLARIS dealer

175

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Warranty

LIMITED WARRANTY

POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED

WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship.

POLARIS further warrants that the spark arrestor in this product will meet the efficiency requirements of USFS

standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation

are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of

purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty

period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The

duration of this warranty may vary by international region based upon local laws and regulations.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to

POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for

warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration

Form will be your proof of warranty coverage. If you have not signed the original registration and received the

customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED

UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your

vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper

dealer set-up will void your warranty coverage.

176

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or

workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This

warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.

This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified,

neglected, improperly maintained, or used for purposes other than for which it was designed.

This warranty excludes damages or failures resulting from: improper lubrication; improper engine timing;

improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or

abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other

foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or

unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty

period expires or by an unauthorized repair center.

177

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect

in materials or workmanship and provides no coverage for consumable components, general wear items, or any

parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were

not designed or not intended, including but not limited to the following items:

•

Wheels and tires

Suspension components

Brake components

Seat components

Clutches and components

Steering components

Batteries

Light bulbs/Sealed beam lamps

Filter

Lubricants

•

Finished and unfinished surfaces

Carburetor/Throttle body components

Engine components

Drive belts

Hydraulic components and fluids

Circuit breakers/Fuses

Electronic components

Spark plugs

Sealants

Coolants

Bearings

Bushings

178

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of

POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this

warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels,

meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of

profits, or loss of vacation or personal time.

179

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS’ OPTION,

REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE

REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY

PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY

PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,

WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,

INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY

FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS

LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO

THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE

SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED

IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF

IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF

INCONSISTENT WITH CONTROLLING STATE LAW.

180

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Warranty

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting

warranty service you must present your copy of the Warranty Registration From to the dealer. (THE COST OF

TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). POLARIS suggests that

you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty

service.

In the country where your product was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are

traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be

requested from any authorized POLARIS dealer that sells the same line as your product.

Outside the country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased, you should take your

product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the

selling dealer’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be

authorized to perform the warranty repair.

181

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Warranty

HOW TO OBTAIN WARRANTY SERVICE

If 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. Product importation rules vary considerably from country to country.

You may be required to present documentation of your move to POLARIS in order to continue your warranty

coverage. You may also be required to obtain documentation from POLARIS in order to register your product in

your new country. You should warranty register your product at a local POLARIS dealer in your new country

immediately after you move to continue your warranty coverage and to ensure that you receive information and

notices regarding your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the

product was originally purchased, all warranty coverage will be denied. You must nonetheless register your

product under your name and address with a local POLARIS dealer in your country to ensure that you receive

safety information and notices regarding your product.

182

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Warranty

EXPORTED PRODUCTS

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE

BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE

SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received

authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this product’s warranty or service coverage if you have any questions. This policy

does not apply to products registered to government officials or military personnel on assignment outside the

country of the selling dealer’s authorized location. This policy does not apply to Safety Bulletins.

183

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Warranty

EXPORTED PRODUCTS

NOTICE

If Purchased From A Private Party:

If your product is registered outside of the country where it was purchased and you have not followed the

procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind,

other than safety bulletins. Products registered to Government officials or military personnel on assignment

outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require 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 or

in different countries. If any of the above terms are void because of federal, state, local law, all other warranty

terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

184

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Warranty

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle.

POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is

designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission

regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would

cause it to fail to meet these regulations.

The warranty period for off-road vehicles 100cc or greater emissions-certified vehicles starts on the date of

purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers

(3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The

warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original

retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (3100 miles) of

vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions

warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the

vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional

warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts

may be covered subject to the terms of any such paid service contract or paid warranty extension.

185

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Warranty

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions,

and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other

components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited

warranty does not cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

•

Air-induction system

Fuel system

•

Ignition system

Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

•

Aftertreatment devices

Crankcase ventilation valves

•

Sensors

Electronic control units

186

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Warranty

U.S.A. EPA Emissions Limited Warranty

The following parts are considered emission-related components for evaporative emissions:

•

Fuel Tank

Fuel Cap

Fuel Line

Fuel Line Fittings

Clamps*

Pressure Relief Valves*

Control Valves*

Control Solenoids*

Electronic Controls*

•

Vacuum Control Diaphragms*

Control Cables*

Control Linkages*

Purge Valves

Vapor Hoses

Liquid/Vapor Separator

Carbon Canister

Canister Mounting Brackets

Carburetor Purge Port Connector

*As related to the evaporative emission control system.

187

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Warranty

U.S.A. EPA Emissions Limited Warranty

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or

replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS

LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF

THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF

EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT

OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES

IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY

FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF

MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO

THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty

lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

188

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Warranty

U.S.A. EPA Emissions Limited Warranty

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty

does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty

also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing

competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire,

explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS

may deny warranty claims for failures that have been caused by the owner’s or operator’s improper maintenance

or use, by accidents for which POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on

your vehicle. POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that

may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a

potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the

effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

189

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Warranty

U.S.A. EPA Emissions Limited Warranty

California Residents

Certain POLARIS off-road vehicles are available in 49-state and 50-state versions. Only the 50-state models are

certified for sale in California. The 50-state models available for sale in California are identified by the letter “C”

in the model name (e.g., R13UH88A_C). The POLARIS 50-state models are designed and built with features

such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable

California regulations and may void this limited emissions warranty offered by the manufacturer.

If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer

Assistance.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

190

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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 Hours

80 Hours

191

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Maintenance Log

DATE

SERVICE

INTERVAL

TECHNICIAN

SERVICE PERFORMED / COMMENTS

100 Hours

120 Hours

150 Hours

192

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Maintenance Log

DATE

SERVICE

INTERVAL

TECHNICIAN

SERVICE PERFORMED / COMMENTS

193

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Maintenance Log

DATE

SERVICE

INTERVAL

TECHNICIAN

SERVICE PERFORMED / COMMENTS

194

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Index

Age Restrictions . . . . . . . . . . . . . . 13

Air Filter . . . . . . . . . . . . . . . . 140-141

Axle and Wheel Nuts . . . . . . . . . 146

Choke Lever. . . . . . . . . . . . . . . . . . 58

Cleaning . . . . . . . . . . . . . . . . . . . . 153

Clothing . . . . . . . . . . . . . . . . . . . . . 11

Constant Variable Transmission . 120

Consumer Product Safety. . . . . . . . . 9

CVT Drying . . . . . . . . . . . . . . . . . 121

CVT System. . . . . . . . . . . . . . . . . 120

Cylinder Head Torque . . . . . . . . . 118

Electronic Throttle Control . . . . . . 61

Emission Control Systems . . . . 96-97

Engine Start Button. . . . . . . . . . . . 59

Engine Stop Switch. . . . . . . . . . . . 58

Equipment Modifications . . . . . . . 12

Exhaust, Exposure to. . . . . . . . . . . 15

Eye Protection . . . . . . . . . . . . . . . . 11

Battery . . . . . . . . . . . . . . . . . 150-153

Installation / Connections . . 152

Removal. . . . . . . . . . . . . . . . 151

Storage. . . . . . . . . . . . . 153, 157

Boots . . . . . . . . . . . . . . . . . . . . . . . 11

Brake Adjustment, Front. . . . 130-131

Brake Adjustment, Rear . . . . . . . 132

Brake Freeplay . . . . . . . . . . . 129-132

Brake Freeplay Specifications . . 129

Brake Lever Travel . . . . . . . . . . . 133

Brake Levers. . . . . . . . . . . . . . . . . 44

Brake, Parking . . . . . . . . . . . . . . . 64

Brakes . . . . . . . . . . . . . . . . . . . . 63-64

Break-in Period. . . . . . . . . . . . . 69-71

Fuel Filter . . . . . . . . . . . . . . . . . . 113

Fuel Safety . . . . . . . . . . . . . . . . . . 15

Fuel Stabilizer . . . . . . . . . . . . . . . 158

Fuel System. . . . . . . . . . . . . . . . . . 66

Fuel Valve . . . . . . . . . . . . . . . . . . . 67

Daytime Running Lights . . . . . . . 149

Drive Chain . . . . . . . . . . . . . . . . . 137

Drive Chain Slack . . . . . . . . . . . . 138

Drive Chain Slack Adjustment . . 139

Driving Downhill . . . . . . . . . . . . . . 87

Driving in Reverse . . . . . . . . . . . . . 81

Driving on a Sidehill . . . . . . . . . . . 86

Driving on Slippery Surfaces. . 82-83

Driving Over Obstacles . . . . . . . . . 91

Driving Procedure . . . . . . . . . . . . . 79

Driving Through Water . . . . . . 92-93

Driving Uphill . . . . . . . . . . . . . 84-85

Gas Cap . . . . . . . . . . . . . . . . . . 43, 66

Gasoline Handling. . . . . . . . . . . . . 15

Gearcase Capacity. . . . . . . . . . . . 115

Gloves . . . . . . . . . . . . . . . . . . . . . . 11

Camber and Caster . . . . . . . . . . . 136

Carburetor . . . . . . . . . . . . . . . 124-125

Carburetor Jetting

OUTLAW 90. . . . . . . . . . . . 164

SPORTSMAN 90 . . . . . . . . 167

195

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Index

Handlebar Adjustment . . . . . . . . . 142

Hauling Cargo . . . . . . . . . . . . . 94-95

Helmet . . . . . . . . . . . . . . . . . . . . . . 10

Horn . . . . . . . . . . . . . . . . . . . . . . . . 59

Horn Button . . . . . . . . . . . . . . . . . . 41

Main Key Switch. . . . . . . . . . . . . . 57

Maintenance Chart. . . . . . . . . 98-105

Making Turns . . . . . . . . . . . . . . . . 80

Modifications. . . . . . . . . . . . . . . . . 12

Safe Operation Practices. . . . . . 74-75

Safety Labels

Age Warning . . . . . . . . . . . . . . 32

Clutch Cover Warning. . . . . . . 38

Discretionary Warning . . . . . . 34

No Passenger Warning . . . . . . 36

Operation Warning . . . . . . . . . 33

Passenger Warning . . . . . . . . . 36

Rack Warning . . . . . . . . . . . . . 37

Tire Pressure Warning. . . . . . . 35

Safety Labels and Locations. . . 32-38

Safety Training . . . . . . . . . . . . . . . 8-9

Safety Warnings . . . . . . . . . . . 13-30

Age Restrictions. . . . . . . . . . 13

Carrying a Passenger. . . . . . . 17

Crossing Hillsides. . . . . . . . . 23

Descending Hills Improperly . 22

Excessive Speeds . . . . . . . . . 19

Exposure to Exhaust . . . . . . . 15

Failure to Inspect . . . . . . . . . 16

Frozen Bodies of Water. . . . . 30

Handling Gasoline . . . . . . . . 15

Hot Exhaust Systems . . . . . . 30

Improper Cargo Loading . . . . 29

Improper Hill Climbing. . . . . 21

Oil . . . . . . . . . . . . . . . . . . . . . . . . 108

Oil Change, Engine . . . . . . . 110-112

Oil Change, Transmission . . . . . . 115

Oil Check, Engine . . . . . . . . . . . . 109

Oil Check, Transmission . . . . . . . 114

Oil, Engine. . . . . . . . . . . . . . . . . . 108

Operator Restrictions. . . . . . . . . . . 13

Indicator Light . . . . . . . . . . . . . . . 148

Indicator Lights . . . . . . . . . . . . . . . 65

Instruction, Operating. . . . . . . . . . . 14

Key Switch . . . . . . . . . . . . . . . . . . . 57

Kick-Start Lever. . . . . . . . . . . . 42, 68

K-Turn . . . . . . . . . . . . . . . . . . . . . . 88

Parking on a Hill or Incline . . . . . . 90

Periodic Maintenance Chart . 98-105

Polaris Products. . . . . . . . . . 168-169

Polishing . . . . . . . . . . . . . . . . . . . 156

Pre-Ride Inspection . . . . . . . . . 72-73

Lamp Replacement

Daytime Running Lights. . . . 149

Indicator Light. . . . . . . . . . . . 148

Tail Light. . . . . . . . . . . . . . . . 147

Lights . . . . . . . . . . . . . . . . . . . . . . . 65

Lights, Daytime Running . . . . . . . 149

Lights, Indicator . . . . . . . . . . . . . . . 65

Lubrication Guide . . . . . . . . 106-107

Restrictions, Age . . . . . . . . . . . . . . 13

Riding Gear . . . . . . . . . . . . . . . 10-11

196

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Index

Safety Warnings . . . . . . . . . . . 13-30

Improper Tire Maintenance. . 26

Improper Modifications . . . . 27

Jumps and Stunts . . . . . . . . . 20

Operating a Damaged ATV. . 30

Operating on Pavement . . . . 18

Operating on Public Roads . . 18

Operating on Steep Hills. . . . 21

Operating Over Obstacles . . . 27

Operating in Deep Water . . . 28

Operating Without Instruction 14

Physical Control of the ATV. 19

Physical Skills. . . . . . . . . . . 30

Protective Apparel . . . . . . . . 16

Skidding or Sliding . . . . . . . 27

Slippery Terrain. . . . . . . . . . 25

Stalling While Climbing a Hill 24

Turning Improperly . . . . . . . 20

Unauthorized Use of the ATV 30

Unfamiliar Terrain . . . . . . . . 26

Using Alcohol or Drugs . . . . 17

Shock Spring Adjustment . . . . . . 136

Sidehilling . . . . . . . . . . . . . . . . . . . 86

Signal words. . . . . . . . . . . . . . . . . . . 6

Spark Arrester . . . . . . . . . . . 122-123

Spark Plug Change. . . . . . . . . . . . 117

Spark Plugs . . . . . . . . . . . . . 116-117

Specifications

Tail Light. . . . . . . . . . . . . . . . . . . 147

Tether Strap. . . . . . . . . . . . . . . . . . 45

Throttle . . . . . . . . . . . . . . . . . . . . . 60

Throttle Cable Adjustment . . . . . 128

Throttle Control. . . . . . . . . . . . . . . 41

Throttle Lever . . . . . . . . . . . . . . . . 61

Throttle Stop Speed Control . . . . 127

Tire Tread Depth. . . . . . . . . . . . . 144

Tires. . . . . . . . . . . . . . . . . . . . . . . 143

Toe Alignment . . . . . . . . . . . 134-135

Transmission Oil . . . . . . . . . . 114-115

Transporting the ATV. . . . . . . . . 161

Turning Around on a Hill . . . . . 88-89

OUTLAW 90 . . . . . . . . 162-164

SPORTSMAN 90 . . . . . 165-167

Speed Control System . . . . . 126-127

Start Button . . . . . . . . . . . . . . . . . . 59

Starting the Engine. . . . . . . . . . 76-77

Steering Inspection. . . . . . . . . . . . 136

Stop Switch . . . . . . . . . . . . . . . . . . 58

Stopping the ATV . . . . . . . . . . . . . 46

Stopping the Engine. . . . . . . . . . . . 78

Storage . . . . . . . . . . . . . . . . . 157-160

Switches

Vehicle Identification Numbers . . 56

Vehicle Immersion . . . . . . . . 118-119

Engine Start Button. . . . . . . . . 59

Engine Stop Switch. . . . . . 41, 58

Horn Button . . . . . . . . . . . . . . 41

Ignition Switch . . . . . . . . . . . . 45

Main Key Switch . . . . . . . . . . 57

Tether Switch . . . . . . . . . . . . . 45

Washing the ATV . . . . . . . . . . . . 154

Wheel Hub Tightening . . . . . . . . 146

Wheel Installation . . . . . . . . . . . . 145

Wheel Nuts . . . . . . . . . . . . . . . . . 146

Wheel Removal. . . . . . . . . . . . . . 144

Safety Words and Symbols. . . . . . .

Seat Latch . . . . . . . . . . . . . . . . . . . 43

Severe Use . . . . . . . . . . . . . . . . . . 99

Shift Lever . . . . . . . . . . . . . . . 42, 62

197

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