Polaris Sportsman 90, Safety And Maintenance Manual

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Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ...Indicates a potential hazard which could result in severe injury or death ...

Page 4: ...daries and adhere to them keeping your child s safety foremost in your mind Never allow your child to operate this machine without adult supervision CHILDREN Before you ride your new Polaris ATV there are some important things you should know How to keep safe is the most important thing You must also learn some things that will keep you and those around you safe while you are riding ...

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Page 6: ...nual is furnished to ensure that the operator and parents are aware of safe operating procedures It also includes information about the general care and main tenance of your ATV Carefully read the following pages If you have any questions regarding this ATV con tact a Polaris dealer for assistance Remember Polaris dealers have the knowledge and facilities to provide you with the best service possi...

Page 7: ...ATV are thoroughly inspected at various intervals All information in this manual is based upon the latest product data and specifications available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Indus...

Page 8: ... safely Parents should supervise their child s use of the ATV at all times Parents should permit continued use only if they determine that the child has the ability and maturity to operate the ATV safely Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH Read this manual and all labels carefully and follow the operating procedures de scribed Never operate...

Page 9: ... video and taken and passed a Polaris approved riding skill test Always avoid operating an ATV on any paved surfaces including sidewalks drive ways parking lots and streets Never operate an ATV on any public street road or highway even a dirt or gravel one Never operate an ATV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves bo...

Page 10: ... when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV Never operate on excessively rough slippery or loose terrain Always follow proper procedures for turning as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at ex cessive speed Always have the ATV checked by an authorized Polaris ...

Page 11: ...ual Check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible Always follow proper procedures for crossing the side of a hill as described in this manual Avoid hills with excessively slippery or loose s...

Page 12: ...lways follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con trol Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth pg 98 go...

Page 13: ...T ATV SAFETY call the Consumer Product Safe ty Commission at 1 800 638 2772 or Polaris at 1 800 342 3764 Additional Important Information Due to our concern for the safety of our customers and the general public Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any...

Page 14: ...in this manual This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals NOTE The addition of certain accessories may change the handling characteristics of the ATV Be certain any accessories added to this ATV have been approved by Polaris Familiarize yourself with their function and affect...

Page 15: ... AND DESCRIPTION OF LABELS 5 19 DAILY PRE RIDE CHECK 20 21 OPERATION WARNINGS 22 46 VEHICLE IDENTIFICATION NUMBERS 47 48 CONTROL AND PARTS FUNCTIONS 49 69 STARTING THE ENGINE 70 71 RIDING GEAR 72 73 VEHICLE BREAK IN PERIOD 74 76 CARRYING LOADS 77 80 DAILY PRE RIDE CHECK 81 83 RIDING 84 103 ...

Page 16: ...ONTENTS PVT SYSTEM OPERATION 104 105 BATTERY 106 111 NOISE EMISSION CONTROL SYSTEM REGULATION 112 114 MAINTENANCE 115 163 SPECIFICATIONS 164 170 WIRING DIAGRAMS 171 172 TROUBLE SHOOTING 173 174 WARRANTY 175 180 INDEX ...

Page 17: ...R 1 RIDER S SECTION ...

Page 18: ... Polaris Youth ATVs are equipped with an Adjustable Throttle Stop System and Exhuast System Restrictor s to allow adults to limit the speed of the vehicle according to the rider s skill and experience More information on speedlimiting functions can be found on pages 134 136 in the maintenance section of this manual CHILDREN Before you ride your new Polaris ATV there are some important things you s...

Page 19: ...tention when you see this symbol This is the safety alert symbol When you see this symbol on your machine or in this manual it means PAY ATTENTION If you don t you could get hurt very badly or even killed Your safety is in volved ...

Page 20: ...Switch A When the engine is running you can push this button down to shut the engine off The button should be up on before starting the engine 2 Throttle Control B This makes your ATV go forward when you press it with your thumb You must always make sure the throttle control does not stick before you operate your ATV Read more about it on page R 12 1 2 B A ...

Page 21: ...ick Starter B If your battery is too weak to start your machine you can push on this with your foot to start the engine Have an adult show you how this works There is more information on how to use the kickstart on page 69 3 B ...

Page 22: ...R 6 KNOW YOUR MACHINE 4 Gas Cap This is where the gas goes that will run your ATV Your ATV will not run without gas Only adults should fill the gas tank 1 4 Always have an adult put gas in your machine ...

Page 23: ...trols the front brake The left hand lever C 2 controls the rear brake To slow down or stop squeeze both brake handles at the same time 5 C 1 C 2 Always apply both brakes at the same time or loss of vehicle con trol can occur resulting in serious injury or death Always take your thumb off the throttle control when you pull the brake lever ...

Page 24: ... Ignition Switch This key must be turned on before pushing the starter button You can also use this key to turn off the engine You can find it on the Right hand side of the Scramblers D and on the pod of the Sportsman E D E 6 ...

Page 25: ... off the switch and the engine will stop Put one end of the tether strap around your right wrist The other end must be attached to the ATV Always attach the tether strap before you ride Sportsman F and Scramblers G F G 7 Never ride without the tether strap attached to your right wrist and machine Be careful not to get the cord tangled around the handlebars or any part of your body ...

Page 26: ...UR MACHINE Let s review the three ways to stop your ATV 1 Sliding the shut off switch to the left or right 2 Disconnecting the tether strap will shut off the engine 3 Turning the key to off will shut off the engine ...

Page 27: ...R 11 KNOW YOUR MACHINE 1 2 3 ...

Page 28: ...ese things now Make sure the throttle doesn t stick Check this by pushing the 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 open you have a sticky throttle This means that something is wrong or broken If you have a sticky throttle do not start the engine You could get hurt if you ride when you h...

Page 29: ... back to where they were before you squeezed If they go back slowly or stay on your brakes are sticking If you have used the storage area under the seat make sure the seat is locked and in place If you have sticky brakes do not start the engine You could get hurt if you ride when you have sticky brakes Have an adult or your Polaris Dealer fix the sticky brakes ...

Page 30: ...to your ATV they must read the instructions and warnings on page 60 in this Owner s Manual Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running It could burn you Children should never check the oil on their own An adult should be in charge of keeping the gas and oil levels to the full marks Always have an adult put gas in your machine ...

Page 31: ...ast check is done with the engine running You must check to make certain that ALL THREE WAYS TO STOP your ATV are working the way they should Do you remember what they are If you cannot list them go back to page R 10 and review ...

Page 32: ... is the most important thing Let s learn how to ride Your 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 Make sure you know where you are going to drive when your ATV is started Make sure the area is safe all around your ATV You must always follow the safe riding rules found on the next page...

Page 33: ...will need a good helmet with a face shield or goggles Wear a long sleeved shirt or jacket gloves long pants and boots Make sure your clothing fits properly If it is too small it could keep you from moving easily If it is too big it could hang down and get caught in a moving part L L L L L L ...

Page 34: ...drive within the sight of an adult Never ride on public trails Always drive your ATV while sitting down Keep both hands on thehandlebars and keep both feet on the running boards You must always follow the safe riding rules found on the next pages If you do not you could be hurt really bad or even killed ...

Page 35: ...on t ride at night Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them Never ride on frozen water You could get hurt or you could even die All ice can be dangerous Always be alert and pay attention to where you are driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do ...

Page 36: ...ride your ATV where you know it is safe to drive No driving over the flower garden or on the little trees you planted Be careful of the things around you Always attach the tether strap to your right wrist and machine before riding Respect your ATV respect your environment and you will earn the respect of everyone ...

Page 37: ...ty to teach their children the proper and safe way to ride any ATV This should be done by reading the owner s manual with your children be fore they first use the ATV and periodically afterwards SAFETY TRAINING When you purchased this vehicle your dealer offered a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed material and a vi...

Page 38: ...uthorized Polaris dealer Failure to follow the warnings contained in this manual can result in severe INJURY OR DEATH NOTE Illustrations used in this manual are for general representation only Your model may differ SAFETY ALERT WARNINGS identify special instructions or procedures which if not correctly followed could result in personal injury or loss of life Read all WARNINGS in this manual carefu...

Page 39: ...out this manual to convey the following messages This is the safety alert symbol When you see this symbol on your machine or in this manual be alert to the potential for personal injury Your safety is involved Indicates a potential hazard which could result in severe injury or death ...

Page 40: ...t this manual to convey the following messages Indicates a potential hazard which may re sult in minor personal injury or damage to the ATV NOTE The word NOTE in this manual will alert you to key information or instructions Indicates a situation that can result in damage to the machine ...

Page 41: ...rotection of the operator s Read and follow the instructions on each decal carefully In the event any decal be comes illegible or comes off contact your Polaris dealer for a replacement Any safe ty decal needing replacement will be provided by Polaris at no charge The part num ber is printed on the decal ...

Page 42: ...6 GENERAL SAFETY AND DESCRIPTION OF LABELS 1 WARNING ...

Page 43: ... 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 A...

Page 44: ...ld result in severe injury or death Adult supervision is required Make sure operators follow Owner s Manual and labels Make sure operators watch the safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually S S S S S 2 Found on Scrambler 50 ...

Page 45: ...rol which could result in severe injury or death S Adult supervision is required S Make sure operators follow Owner s Manual and labels S Make sure operators watch the safety video and pass the ATV Training Course S Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ...

Page 46: ...n severe injury or death Adult supervision is required Make sure operators follow Owner s Manual and labels Make sure operators watch the safety video and pass the ATV Training Course Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually S S S S S 7079091 2 Found on Scrambler 90 and Sportsman 90 ...

Page 47: ...ntrol which could result in severe injury or death S Adult supervision is required S Make sure operators follow Owner s Manual and labels S Make sure operators watch the safety video and pass the ATV Training Course S Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ...

Page 48: ...LS IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE PSI FRONT 3 REAR 3 maximum weight capacity Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS _____ LBS 3 3 4 WARNING ...

Page 49: ...13 GENERAL SAFETY AND DESCRIPTION OF LABELS 4 WARNING Indicates a potential hazard which could result in severe injury or death ...

Page 50: ...14 GENERAL SAFETY AND DESCRIPTION OF LABELS 5 6 ...

Page 51: ... dam age the engine DClean air filter often more frequent cleaning required in dusty conditions 5 on rear of seat 6 DSpecific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory Setting D40 to 80 F at 0 3000 feet 5 to 27 C at 0 900 meters On air filter box ...

Page 52: ...16 GENERAL SAFETY AND DESCRIPTION OF LABELS 7 10 8 8 ...

Page 53: ...rd removed 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 DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 10 lbs Rear 20 lbs 8 Found on the Sportsman 90 WARNING WARNING ...

Page 54: ...WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 423 LBS Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unse cured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly se cured to the racks With dual racks load distribution 1 3 front 2 3 rear is be...

Page 55: ...nt situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer ...

Page 56: ...ion and pressures 2 Fuel and oil tanks fill both tanks to their proper levels 3 All brakes check operation adjustment 4 Throttle check for free operation and closing 5 Brakelight check for proper operation This ATV must be inspected each time before riding to ensure it is in proper working order If proper inspection is not done severe injury or death could result WARNING ...

Page 57: ...tion and slack refer to drive chain adjustment 9 Air cleaner element check for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 12 Operators helmet goggles and clothing Indicates a potential hazard which could result in severe injury or death WARNIN...

Page 58: ... for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD Follow the age guidelines printed on your machine WARNING ...

Page 59: ...reduces your ability to balance and control this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed during op eration It is not for carrying passengers WARNING ...

Page 60: ...N HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever pos sible If you must ride on a paved surface go slowly and do not make sudden turns or stops WARNING ...

Page 61: ...ts roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states it is illegal to operate ATVs on pub lic streets roads and highways WARNING ...

Page 62: ... chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants WARNIN...

Page 63: ...g alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV WARNING ...

Page 64: ...es your chances of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain visibility and operating conditions and your experience WARNING Indicates a potential hazard which could result in severe injury or death WARNING ...

Page 65: ...TIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps Don t try to show off WARNING ...

Page 66: ...he ATV WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the Owner s Manual WARNING ...

Page 67: ... your ability to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may come into contact with the rear wheels which could injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation WARNING ...

Page 68: ... CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV WARNING ...

Page 69: ...ould cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain Always be especially cautious on these kinds of terrain WARNING ...

Page 70: ...uld go out of control causing a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner s Manual See page 86 Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed WARNING ...

Page 71: ...as described in the Owner s Manual See pages 91 through 96 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly The ATV could flip over backwards 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 othe...

Page 72: ...ing down hills as described in the Owner s Manual See page 94 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill where possible WARNIN...

Page 73: ...ny hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 96 Be very careful when turning on any hill Avoid crossing the side of a steep hill if possible When crossing the side of a hill Always follow proper procedures as described in the Owner s Manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill si...

Page 74: ...ly the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly by squeezing the RH lever When fully stopped apply rear brake as well and then lock parking brake Dismount on uphill side or to either side if pointed straight uphill Turn the ATV around and...

Page 75: ...also regain traction unexpectedly which may cause the ATV to over turn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control WARNING Indicates a potential hazard which could result in severe injury or death WARNING ...

Page 76: ...ol or a collision Could cause the ATV to overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Use extreme caution when riding over large obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual WARNING ...

Page 77: ...NTIAL HAZARD Riding on frozen lakes and rivers WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator break through the ice HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water WARNING ...

Page 78: ...ep or fast flowing water If you canot avoid water which exceeds the recommended maximum depth go slowly balance your weight carefully avoiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes See page 98 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary app...

Page 79: ...es on this ATV or operation of this ATV with improper or un even tire pressure may cause loss of control and increases the risk of an acci dent HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner s Manual Supplement for this vehicle Always maintain proper tire pressure as described in the Owner s Manual Sup plement WARNING ...

Page 80: ...oading this ATV WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached WARNING ...

Page 81: ...ossible damage Safe operation of this rider active vehicle requires good judgement and physi cal skills Persons with cognitive or physical disabilities who operate this ve hicle have an increased risk of overturns and loss of control which could re sult in severe injury or death WARNING WARNING Indicates a potential hazard which could re sult in severe injury or death WARNING ...

Page 82: ...some situations could lead to an accident HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories All parts and accessories added to this vehicle should be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to instructions If you have questions consult an authorized Polaris ATV de...

Page 83: ...47 VEHICLE IDENTIFICATION NUMBERS 2 1 ...

Page 84: ...e spare key and store in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important for model identification when registering your vehicle obtaining insurance or whenever replacement parts are required In the event your vehicle were stolen these numbers are essent...

Page 85: ...gine Electrical Switches 1 Main Switch Located on the Right hand side of the Scram blers A and on the pod of the Sportsman B This switch is op erated with a key and must be turned clockwise to the on posi tion to start the engine A B 1 ...

Page 86: ...s in its off position Its purpose is to provide the operator with a quick means of engine shut down in case of stuck throttle or other emer gency NOTE Both the main switch and the emergency engine stop switch shut off all elec trical power to the entire vehicle To stop the engine push the on off button C down 2 C ...

Page 87: ...the tether switch is securely plugged into the machine and attached to the rider s right wrist Turn the key to the on position set the parking brake push the start but ton up to the on position and engage the starter D NOTE Remember to release the park brake before driving forward 3 C D ...

Page 88: ...en without the park brake released CAUTION This ATV is not equipped with lighting This ATV is designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility Do not operate this ma chine after dark WARNING ...

Page 89: ... accident resulting in severe injury or death Always contact your dealer for service repairs whenever throttle problems arise Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during riding and cause an accident Always check the lever for free movement and return before starting the en gine and occasionally during riding WARNING ...

Page 90: ...and engine speed returns to idle when the lever is released This vehicle is equipped with an Electronic Throttle Control ETC which is designed to re duce the risk of a frozen or stuck throttle In the event the throttle cable should stick in an open position the engine will stop and power to the rear wheels will cease when the operator re leases the throttle lever 1 ...

Page 91: ...The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanism WARNING ...

Page 92: ...s a main switch It is located on the right hand side of the machine or headlight pod and operated with a key Indicator Lights Each Polaris ATV has indicator lights This model has a low oil warning light When this red dot is lit it is indicating a low oil level ...

Page 93: ...e rear brake A squeeze the left hand lever to ward the handlebar The front brakes B are activated by squeezing the lever on the RH handlebar A B Always apply both brakes at the same time or loss of vehicle con trol can occur resulting in serious injury or death WARNING ...

Page 94: ...2 Push the park brake lock B down This will pre vent the lever from returning to the released position Always check to be sure that the parking brake has been disengaged before operating the ATV An accident could result causing severe injury if the parking brake is left on while the ATV is operated WARNING A B ...

Page 95: ...efore starting the engine Always lock the parking brake whenever the vehicle is left unattended Before starting the engine make certain the park brake is fully locked Since the machine has a transmission that is always in forward throttle activation to warm the engine will make the machine go forward if the park brake is not locked Once the engine has warmed enough for operation release the park b...

Page 96: ...rks in or near the area where re fueling is performed or where gasoline is stored D Do not over fill the tank Do not fill the tank neck D If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing D Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and de...

Page 97: ...S FUNCTIONS Indicates a potential hazard which could result in severe injury or death WARNING WARNING The engine exhaust from this prod uct contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 98: ... system Doing so may reduce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components D Routine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See your dealer D This PVT system is intended for use on...

Page 99: ...NS Engine Fuel and Oil System Fuel System The fuel tank filler cap 1 is located directly behind the handlebar The tank has a capac ity of 1 3 gallons 5 liters Use unleaded gas oline with a minimum pump octane number of 87 octane 1 ...

Page 100: ...never transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after having used the reserve supply Always return valve to on position after re fueling machine Scrambler Fuel Valve Sportsman Fuel Valve ...

Page 101: ...r should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter Use only Polaris injection oil Never substitute or mix oil brands Serious en gine damage and voiding of warranty can result To avoid serious engine damage always top off the oil level when refueling CAUTION ...

Page 102: ...ar of the cab and pull back on the seat latch To replace the seat set it in place and push down on the rear of seat Always make sure the seat is locked in place be fore riding 1 Do not attempt to release the seat latch unless the machine has not been run for at least an hour The exhaust gets very hot when the ma chine is run and can cause serious burns CAUTION ...

Page 103: ... available for use in all our products and highly recommends their use The only oils recommended for Polaris 2 cycle ATVs are Po laris Premium 2 cycle oil or Premium Gold Synthetic 2 cycle oil Engine warranty coverage may become void if you use a brand other than Polaris in your machine CAUTION ...

Page 104: ...ty technology they excel in meeting the lubrication demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are the best available in the market today Premium 2 Cycle Oil Polaris also has a TC W3 premium oil available for use in all of our 2 cycle products We highly recommend its use if premium go...

Page 105: ...our vehicle is on a level surface and the parking brake is set See page 58 2 Fold out the kick start lever A which is on the left hand side of the machine 3 Turn the key to ON and make sure the stop switch is in the RUN position 4 Placing your foot on the kick start push your heel downward to crank the engine 5 Once the engine has started fold the kickstart lever back into place A ...

Page 106: ...result in severe injury or death WARNING Never run an engine in an enclosed area Carbon monoxide exhaust gas is poisonous and can cause severe injury or death Always start engines outdoors WARNING You must allow your vehicle adequate warm up time before operating or en gine damage could result CAUTION ...

Page 107: ... engaged or the en gine will not start 8 Do not press the throttle while starting the engine 9 Activate the starter for a maximum of five seconds releasing the button when the vehicle starts If engine does not start release the starter and wait five seconds then activate the starter for another five seconds Repeat this procedure until en gine starts After the engine starts vary the engine RPM slig...

Page 108: ...ce chances of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet which meets or exceeds your state s safety standards and bears either the De partment of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label L L L L L L ...

Page 109: ...tterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf type boots with heels such as moto cross boots 5 Clothing To protect your body long sleeves and pants should always be worn Riding pants with kneepads a jersey and shoulder pads provide the best pro...

Page 110: ...atment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully 1 Mix 6 4 ounces of injection oil to two gallons of gasoline in a suitable gas can Fill the fuel tank as outlined on page 65 2 Fill the oil tank with Polaris injection oil Use only Polaris injection oil Never substitute or mix oil brands Serious engine damage a...

Page 111: ... throttle positions 5 Perform regular checks on fluid levels controls and all important areas on the ve hicle as outlined earlier on the daily pre ride inspection checklist found on page 20 Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts CAUTION ...

Page 112: ...er the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see your dealer for oil pump bleeding and repeat the pre mix procedure Fill the oil tank when you refuel your ATV If you don t serious engine damage could result CAUTION ...

Page 113: ...e speed and cargo to maintain stable driving conditions Never exceed the weights specified and never attempt to carry cargo on the Scrambler models Correct loading of this vehicle is necessary to maintain proper stability and oper ating characteristics Overloading or incorrect positioning of the load affects the vehicle s turning stopping distance and stability Failure to follow loading require me...

Page 114: ...w the warnings listed below D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO D CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle tip over ...

Page 115: ...uld result in loss of control of the vehicle D LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the ve hicle and creates a less stable operating condition When cargo loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions D OPERATE ONLY WITH STABLE AND SAFELY ARRANGED L...

Page 116: ...TREME CAUTION MUST BE USED when operating with loads ex tending over the rack sides Stability and maneuverability may be ad versely affected causing the machine to overturn D DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS ...

Page 117: ...81 DAILY PRE RIDE CHECK You must inspect your ATV each time before riding to ensure it is in proper working order If proper check is not done severe injury or death could result WARNING ...

Page 118: ...ndition and pressures 2 Fuel and oil tanks fill both tanks to their proper levels 3 All brakes check operation and adjustment 4 Throttle check for free operation and closing 5 Brakelight check for proper operation 6 Engine stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins ...

Page 119: ...k for dirt clean or replace 10 Steering check for free operation noting any unusual looseness in any area 11 Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fas teners 12 Operators helmet goggles and clothing Indicates a potential hazard which could result in severe injury or death WARNING ...

Page 120: ...84 RIDING ...

Page 121: ...t to warm up 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly practice maneuvering and using the throttle and brakes on level sur faces ...

Page 122: ...86 RIDING Making Turns ...

Page 123: ...r 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 smooth ly Avoid turning at sharp angles Tipover and severe inju...

Page 124: ...88 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or dur ing cold freezing weather special attention must be paid to prevent vehicle turnover ...

Page 125: ...of the skid and shifting your body weight forward 4 Never apply brakes during a skid Complete loss of ATV control can result 5 Do not operate on excessively slippery surfaces if possible to avoid 6 Always reduce speed and use additional caution Failure to exercise care when operating the ATV on slippery surfaces can be dangerous Loss of tire traction and vehicle control can result in an accident i...

Page 126: ...90 RIDING Traveling Uphill 15_ Maximum ...

Page 127: ... rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV Do not operate this machine on hilly terrain If you cannot avoid operating in hilly terrain use extreme caution Braking and handling are greatly affected Loss of vehicle control or overturning of the ATV could occur causing severe injury or death WARNING ...

Page 128: ...92 RIDING Sidehilling ...

Page 129: ... body weight up hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can be dangerous Loss of vehicle control or overturning of the ATV could occur causing severe injury or death WA...

Page 130: ...94 RIDING Traveling Downhill ...

Page 131: ...ur weight to the rear of the vehicle 3 Slow down 4 Apply the the front and rear brakes at the same time and very slightly to aid in slow ing Do not travel at excessive speeds It is dangerous and can cause loss of vehicle control and tipping resulting in severe injury or death WARNING ...

Page 132: ...ING Turning Around On A Hill 8 Uphill If the ATV stalls while climbing a hill never back it down the hill One maneuver which can be used when it is necessary to turn around while climbing a hill is the K turn ...

Page 133: ... and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward 6 Lock the parking brake and remount ATV from the uphill side maintaining body weight uphill 7 Restart engine release parking brake and proceed slowly controlling speed with the service brake until ATV is on reasonably level ground Avoid climbing steep hills Loss of vehicle control or over...

Page 134: ...98 RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the foot rests ...

Page 135: ...e D Avoid operating the ATV through deep or fast flowing water If you cannot avoid water which exceeds the recommended maximum depth go slowly bal ance 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 NOTE If the vehicle is run in water it is critical the machine is serviced as out lined...

Page 136: ...100 RIDING Trail Obstacles ...

Page 137: ...e and be constantly alert for hazards such as logs rocks and low hanging branches Indicates a potential hazard which could result in severe injury or death WARNING Not all obstacles are visible Travel with caution on trails severe injury or death can result if your machine comes in contact with a hidden obstacle WARNING ...

Page 138: ...102 RIDING Parking on an Incline ...

Page 139: ...le is Parked 1 Turn the engine off 2 Set the parking brake 3 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown on the facing page 4 Shut off fuel supply ...

Page 140: ...stem Doing so may re duce its strength so that a failure may occur at high speeds This system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on compo nents D Routine maintenance is the responsibility of the owner Always follow recommended maintenance procedures See your dealer D This PVT system is intended for use on ...

Page 141: ...move the screws and the crankcase cover 2 Remove the screws and the filter cover 3 Soak the filter in a mild detergent and rinse with clean water 4 Allow the filter to air dry and reinstall it If your vehicle is operated in salt water areas it must be rinsed with fresh wa ter to prevent corrosion that can be caused by exposure to seawater CAUTION ...

Page 142: ...en to handle a battery or service a battery in any way WARNING Whenever removing the battery disconnect the negative black cable first When reinstalling the battery connect the negative black cable last or an ex plosive situation could result causing serious injury or death WARNING ...

Page 143: ...nal Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEE...

Page 144: ... will deteriorate rapidly Check the battery fluid level often The fluid level should be kept between the upper and lower level marks To refill use only distilled water Tap water contains minerals which are harmful to a battery Maintain between upper and lower level marks ...

Page 145: ...sconnect the red positive battery cable next 4 Lift the battery out of the ATV being careful not to tip it sideways and spill electro lyte Indicates a potential hazard which could result in severe injury or death WARNING If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV CAUTION ...

Page 146: ...on baking soda and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery To avoid the possibility of explosion always connect battery cables in the order specified Red positive cable first black negative cable last An exploding battery can cause serious...

Page 147: ...s placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool dry place D Before reusing take the battery to your dealer for testing and recharging D When installing a new battery make certain it is fully charged prior to it s initial use Using a battery that is not fully charged can damage the battery resulting in a shorter life of the bat...

Page 148: ...gn incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BE LOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alterat...

Page 149: ...placement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance D Be careful when traveling through tall grass The potential for fire exists CAUTION Engine and exhaust parts can become very hot after use Be careful not to touch any engine or exhaust components or serious burns could result ...

Page 150: ...114 NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100 1A ...

Page 151: ...kits are 2 cycle engines D spark plug wrench with Phillips head screwdriver D tire pressure gauge Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication intervals of important components are explained in the following chart on the following pages ...

Page 152: ...qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Service and adjustments are critical If you are not familiar with safe service and ad justment procedures have a qualified dealer perform these operations Due to the natur...

Page 153: ...ide Pre ride Inspect daily pre ride inspection item Wheels Pre ride Pre ride Pre ride inspection item Frame nuts bolts fasteners Pre ride Pre ride Pre ride inspection item Oil Level Daily Daily Check when refueling Air Filter Daily Daily Inspect Clean J Brake pad wear 10 hrs 100 miles Monthly Inspect periodically Battery 20 hrs Monthly Check Terminals clean check fluid level ...

Page 154: ...When Remarks Oil Pump Cable 50 hrs 6 months Inspect adjust lubricate replace if re quired Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage Due to the nature of the adjustments marked with a J on the following chart it is recommended that service be performed by an authorized Polaris dealer CAUTION ...

Page 155: ...item Steering 50 hrs 6 months Inspect daily lubricate Rear Axle 50 hrs 6 months Inspect bearings Lube Front Suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear Suspension 50 hrs 6 months Inspect tighten fasteners Drive Chain 50 hrs 6 months Inspect daily adjust and lubricate if need ed J Clutches drive and driven 100 hrs 12 months Inspect clean ...

Page 156: ... Mounts 100 hrs 12 months Inspect Spark Plug 100 hrs 12 months Inspect replace if necessary J Ignition Timing 100 hrs 12 months Inspect and adjust as needed Due to the nature of the adjustments marked with a J on the following chart it is recommended that service be performed by an authorized Polaris dealer CAUTION ...

Page 157: ... carburetor Re place lines every two years J Fuel Filter 100 hrs 12 months Replace annually Spark arrestor 100 hrs 12 months Clean out J Front wheel bear ings 300 hrs 36 months Inspect replace if necessary J Idle Speed As Re quired As Re quired Adjust J Toe adjustment As re quired As re quired Periodic inspection adjust when parts are replaced ...

Page 158: ...mmendations Item Lube Rec Method Frequency 1 Engine Oil Polaris Injection Oil Fill oil tank See page 63 As needed when refuel ing 2 Transmission Oil Polaris Premium Synthetic gear case lube See Page 148 Change annually or at 100 hours ...

Page 159: ...123 MAINTENANCE Lubrication Recommendations Operating Range 2 Transmission plug ...

Page 160: ...wet or dusty conditions Polaris Premium all Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special Grease every 40 hours or approximately 500 miles or after submerging in water or before long periods of storage or after pressure washing Always use Polaris Premium U Joint Lube for maximum service of these driveline components PN 2871515 3 oz PN 2871551 14...

Page 161: ...125 MAINTENANCE NOTE Hours are based on 10 mph average 4 ...

Page 162: ...NCE Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 25 Hrs 50 Hrs 75 Hrs 100 Hrs ...

Page 163: ...127 MAINTENANCE Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks ...

Page 164: ...adlight pod it will be necessary to remove the upper headlight pod On other models remove the handlebar cover Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars result ing in loss of control and possible serious personal injury or death WARNING ...

Page 165: ...dlebars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 7 3 ft lbs NOTE Tighten bolts so there is an equal gap at the front and rear of the handlebar block Improper gap will result in improp er fit of upper pod ...

Page 166: ...pecifications Specification Front Spindle Nuts 43 ft lbs Rear Spindle Nuts 80 ft lbs NOTE All nuts that have a cotter pin installed must be serviced by an autho rized Polaris Dealer Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component opera tions Service work must be performed by your authorized Polaris dealer ...

Page 167: ...131 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction re quired to increase or decrease spring ten sion Rear Spring Adjustment Cam ...

Page 168: ...r after every 50 hours of operation If the vehicle is ridden in wet or dusty conditions clean the filter more often Never operate the ATV with the filter element removed Dirt will enter the engine causing serious rapid wear and damage to the engine CAUTION ...

Page 169: ...ENANCE To clean the filter 1 Remove the screws on the airbox A and re move the filter B 2 Soak the filter in a mild detergent and rinse it in clean water 3 Let the filter air dry and reinstall in the air box A B ...

Page 170: ...ottle Stop System The throttle stop system controls how far the throttle opens To adjust loos en the jam nut D turn the screw E inward to reduce speed and outward to increase speed Tighten the jam nut after adjusting D E ...

Page 171: ...l The Scrambler 50 utilizes a restrictor at the headpipe exhaust flange and at the spark arrestor Make certain the engine and exhaust system is cool to avoid burns Loosen the set screw A of the exhaust restrictor on the spark arrestor and remove the exhaust restrictor Remove the nuts at the headpipe exhaust flange the center mount bracket bolts and the spark arrestor fasteners A ...

Page 172: ...k arres tor first then the center mount bolt and the head pipe flange nuts last Torque to 10 ft lbs 1 0 kgf m Spark Arrestor Restrictor The Scrambler 90 and the Sportsman 90 utilize a restrictor at the spark arrestor only Make certain the engine and exhaust system is cool to avoid burns Loosen the set screw of the exhaust restrictor on the spark arrestor and remove the exhaust restrictor A ...

Page 173: ...and bolts are found have your dealer tighten them before riding your vehicle Camber and Caster The camber and caster are non adjustable Do not attempt to adjust the tie rod for toe alignment Severe injury or death can result from improper adjustment Contact your Polaris dealer He she has the training and tools to make these adjustments WARNING ...

Page 174: ...nt is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer correct it 1 Set the handlebars in a straight ahead position and hold them in this position NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post ...

Page 175: ...king sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of front rim Rear rim measurement should be 1 16 1 8 2 to 3 cm more than front rim measurement 5 If this measurement needs to be adjusted contact your dealer for service ...

Page 176: ...ment Periodically check the freeplay of the front and rear brakes Refer to the chart below for the acceptable range of freeplay for your ma chine To adjust the front brake turn the adjustment knob A until the freeplay is acceptable A ...

Page 177: ...141 MAINTENANCE To adjust the rear brake turn the adjuster nut B until the proper freeplay is attained B ...

Page 178: ...2 MAINTENANCE Brake Freeplay Adjustment Model Front Rear Sportsman 90 39 78 10 mm 20 mm 39 78 10 mm 20 mm Scrambler 90 39 78 10 mm 20 mm 39 78 10 mm 20 mm Scrambler 50 1 39 2 5mm 9 9 mm 15 30 3 8mm 7 6mm ...

Page 179: ...ore riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5mm 3 2mm C If adjustment is required turn the adjustment nut D until the freeplay falls in to the acceptable limit Indicates a potential hazard which could result in severe injury or death WARNING C D ...

Page 180: ...ion should be read after the engine is warmed up and the vehicle is driven at higher speeds Immediately check the spark plug for correct color 1 Normal The insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulat...

Page 181: ...buretion adjustments Spark Plug Removal and Replacement The spark plug is removed by using the special wrench provided in the tool pouch Remove the spark plug cap and then the spark plug by rotating counterclockwise Reverse the procedure for spark plug installation Torque to 17 ft lbs Never deviate from the recommended spark plug as engine damage can occur Never attempt to remove a spark plug whil...

Page 182: ... fuel tank Run the engine for five min utes to get the additives through the entire fuel system and top off with fuel Fuel additive products are available through your Polaris dealer NOTE Before storing the machine add lubricant to the fuel in the tank at a 40 1 ratio and then run the engine for three to five minutes This will lubricate the fuel pump diaphragm to keep it flexible and help prevent ...

Page 183: ...e Fastener Torque 2 Cycle Models Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours Indicates a potential hazard which could result in severe injury or death WARNING ...

Page 184: ...ricant level should be checked monthly Transmission oil should be changed annually With the ATV on a level surface remove fill plug dipstick and check the lubricant level Lubricant should be kept at the full mark on the dipstick The correct transmission lubricant to use is Polaris Pre mium Synthetic Gearcase Lubricant PN 2871478 A ...

Page 185: ...lug dipstick 2 Remove transmission drain plug and drain the oil Catch and discard used oilprop erly 3 Clean and reinstall the drain plug 4 Add Polaris Premium Synthetic Gearcase Lubricant PN 2871478 12 oz bottle to full mark on the fill plug dipstick 5 Check for leaks ...

Page 186: ...es improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death Follow the safeguards listed below to prevent this type of situation WARNING ...

Page 187: ...es may affect ATV handling Make certain the wheels are installed properly If wheels are improperly installed it could affect vehicle handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts ...

Page 188: ...ze PSI Wheel Nut Torque Scrambler 50 Front 16 x 8 7 2 22 ft lbs Rear 16 x 8 7 2 22 ft lbs Scrambler 90 Front 18 x 7 7 3 22 ft lbs Rear 18 x 9 5 8 3 22 ft lbs Sportsman 90 Front 19 x 7 8 3 22 ft lbs Rear 18 x 9 5 8 3 22 ft lbs ...

Page 189: ...ect position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 2 Attach the wheel nuts and fingertighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts ac cording to the chart found on page 152 ...

Page 190: ...154 MAINTENANCE Tire Inspection When replacing a tire always use original equip ment size and type Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm 1 or less 1 ...

Page 191: ...ary to lubricate the outer surfaces of the roller Regularly lubricate the drive chain with SAE 80 90 lube or an approved O ring chain spray lube Indicates a potential hazard which could result in severe injury or death WARNING Never wash the chain with a high pressure washer or gasoline Damage to the O rings will result causing premature wear and drive chain failure CAUTION ...

Page 192: ...156 MAINTENANCE Drive Chain Inspection and Adjustment Cont The adjuster stud must be held secure when tightening jam nuts or the stud may break CAUTION ...

Page 193: ... Adjustment The normal chain slack should be kept between 40 80 10 20 mm A Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result CAUTION 1 A ...

Page 194: ...stment Procedure 1 Loosen 4 rear housing mount bolts A 2 Tighten chain adjuster B to reduce slack to recommended setting 4 8 10 mm 20 mm 3 Tighten jam nuts on chain adjuster 4 Tighten the four rear housing mount bolts A B ...

Page 195: ...p may need to be replaced 1 From the rear of the brake light remove two screws A holding lens cover in place and remove lens cover B 2 Remove lamp C and replace it with recom mended lamp 3 Test the brakelight to see that it s working 4 Reinstall the lens cover removed in step 1 A B C ...

Page 196: ... pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels Many expensive repair bills can result from using high pressure deter gent systems NOTE If a high pressure car wash is used grease all zerk fittings immediately after washing Also run the vehicle to evaporate any water that might hav...

Page 197: ...and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your a Polaris dealer for free replacement Waxing Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish Certain products including insect repellants and chemicals will damage plastic surfaces Care must be taken when using these p...

Page 198: ...d the following measures should be taken 1 Turn the fuel valve to off 2 Be certain the fuel cap oil cap and seat are installed correctly 3 Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope 4 Always lock the parking brake ...

Page 199: ...gained changes to the carburetor and drive system can be made to allow efficient operation These changes include 1 Carburetor re jetting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss during high altitude operation Contact your dealer 3 On 2 cycle models air screw adjustments can be made to compensate for temper atur...

Page 200: ... Cooled Engine type 2 Stroke Lubrication Oil Injected Oil Capacity 1 1 quarts 1 liter Fuel Capacity 1 3 gallons 5 liters Starting Electric with kick start backup Transmission Automatic CVT Front Suspension A Arm with 2 5 cm of travel Rear Suspension Spring over shock with 4 25 10 8 cm of travel ...

Page 201: ... Parking Brake Mechanical Lock Front Tires PSI 16 x 8 7 2psi Rear Tires PSI 18 x 9 5 8 2psi Turning Radius 74 8 190 cm Wheel Base 35 4 90 cm Dry Weight 211 6 lbs 96 kgs Length 54 6 138 7 cm Width 34 86 3 cm Height 34 7 88 2 cm Brake Light Standard Low Oil Light Standard ...

Page 202: ...oled Engine type 2 Stroke Lubrication Oil Injected Oil Capacity 1 1 quarts 1 liter Fuel Capacity 1 3 gallons 5 liters Starting Electric with kick start backup Transmission Automatic CVT Front Suspension A arm with 4 25 10 8 cm of travel Rear Suspension Spring over shock with 4 25 10 8 cm of travel ...

Page 203: ...Brakes Drum Parking Brake Mechanical Lock Front and Rear Tires PSI 18 x 7 7 2psi Turning Radius 98 4 250 cm Wheel Base 35 4 90 cm Dry Weight 233 7 lbs 106 kgs Length 56 1 142 4 cm Width 34 86 3 cm Height 36 1 91 8 cm Brake Light Standard Low Oil Light Standard ...

Page 204: ... Cooled Engine type 2 Stroke Lubrication Oil Injected Oil Capacity 1 1 qts 1 ltr Fuel Capacity 1 3 ga 5 ltr Starting Electric with kick start backup Transmission Automatic CVT Front Suspension A arm with 4 25 in 10 8 cm of travel Rear Suspension Spring over shock with 4 25 in 10 8 cm of travel ...

Page 205: ...rakes Drum Parking Brake Mechanical Lock Front Tires PSI 19 x 7 8 3 psi Rear Tires PSI 18 x 9 5 8 3 psi Wheel Base 37 8 96 cm Turning Radius 98 4 250 cm Dry Weight 238 1 lbs 108 kgs Length 57 6 146 3 cm Width 34 4 87 4 cm Height 36 6 93 cm Brake Light Standard ...

Page 206: ...w Oil Light Standard Front Rack Capacity 10 lb 4 5 kgs Rear Rack Capacity 20 lb 9 kgs Accessories There are a wide range of Polaris Accessories available forATVs Contact yourPolar is dealer to find out about the accessories available for your machine ...

Page 207: ...171 WIRING DIAGRAM ...

Page 208: ...172 WIRING DIAGRAM ...

Page 209: ... causes for ques tions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE CRANKS BUT FAILS TO START No Fuel Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve or filter ...

Page 210: ...S POWER No Fuel Contact Your Dealer Contact Your Dealer Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Electronic Throttle Control Malfunction Fuel Vent Line Kinked or Plugged ...

Page 211: ...also gives a one year limited war ranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transfer rable to another consumer during the warranty period through a Polaris dealer There is a charge of 35 00 pay...

Page 212: ... THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment 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 ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV ...

Page 213: ... that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upho...

Page 214: ...IS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FORBREACH OFTHIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL 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 Some states do not permit the exclusion or limitation of incidental or consequential damage...

Page 215: ...nty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repairPolaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

Page 216: ... Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Always use Polaris engine oil 2 Neversubstitute ormix oilbrands as serious engine damage and voiding of warran ty can result ...

Page 217: ...ts Functions 49 69 Crossing Streams 98 Cylinder Head Torque 147 Daily Pre ride Inspection 20 21 81 83 Drive Chain Adjustment 155 156 Engine Electrical Switches 49 Engine Start Button 51 Engine Stop Switch R4 50 Exhaust System Restrictor 135 Front Brake R7 Fuel Safety 65 Fuel System 63 Gas Cap R6 General Safety And Description of Labels 5 19 Handlebar Adjustment 128 Ignition Switch R8 Indicator Lig...

Page 218: ...strictor 136 Spark Plugs 144 Specifications 164 170 Starting A Cold Engine 70 Starting The Engine 70 71 Steering Inspection 137 Storage 146 Tether Strap R9 Throttle R4 53 Throttle Cable Adjust 134 135 143 Throttle Lever 54 Tire Inspection 154 Toe Alignment 138 139 Tool Kit 115 Torque Specifications 130 Trail Obstacles 100 Transmission Lubrication 148 Transmission Oil Changing Procedure 149 Transpo...

Page 219: ...183 INDEX Warranty 175 180 Wheel Installation 151 153 Wheel Nut Torque 152 Wheel Removal 151 Wiring Diagram 171 172 ...

Page 220: ...ut 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 passen gers affect balance and steering and increaqse 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 handin...