Read this manual carefully. It contains important safety information.
Adult supervision is required at all times.
Operation is prohibited for anyone under age 10.
OUTLAW 110
SPORTSMAN 110
Owner's Manual for Maintenance and Safety
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.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer,
birth defects or other reproductive harm.
For videos and more
information about a safe
riding experience with your
Polaris vehicle,
scan this QR code with
your smartphone.
1
Visit us at www.polaris.com
2
POLARIS®, SPORTSMAN® and OUTLAW® are trademarks of POLARIS Industries Inc.
Copyright 2016 POLARIS Industries Inc. All information contained within this publication is based on the latest
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
2017 OUTLAW 110 / SPORTSMAN 110 Owner’s Manual
P/N 9927393
3
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.
4
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!
5
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. . . . . . . . . . . . . . . . 67
Emission Control Systems. . . 94
Maintenance . . . . . . . . . . . . . 96
Specifications. . . . . . . . . . . . 158
POLARIS Products . . . . . . . 162
Troubleshooting. . . . . . . . . . 163
Warranty . . . . . . . . . . . . . . . 168
Maintenance Log. . . . . . . . . 183
Index. . . . . . . . . . . . . . . . . . . . . 187
6
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.
The safety alert symbol indicates a potential
personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that,
if not avoided, will result in death or serious
injury.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
A CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
A NOTICE indicates a situation that could result
in property damage.
The Prohibition Safety Sign indicates
an action NOT to take in order to avoid
a hazard.
The Mandatory Action Sign indicates
an action that NEEDS to be taken to
avoid a hazard.
7
Introduction
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+ models are designed for
children not less than 10 years of age and Y-
6+ 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.
WARNING
8
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.
If you purchased a new POLARIS ATV in
the United States, your dealer provided
information about the authorized ATV
RiderCourse
sm
that is available to you and
your eligible family members. This training
is included in the purchase price of your
ATV.
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.
9
Safety
Safety Training
If you purchased a used POLARIS ATV in
the United States, you can enroll in the ATV
RiderCourse
sm
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
information about 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.
10
Safety
Riding Gear
Always wear clothing suited to the type of riding. ATV
riding requires special protective clothing for comfort and to
reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury.
Whenever riding a POLARIS vehicle, always wear a helmet
that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
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.
Helmet
Eye Protection
Gloves
Over-the-Ankle
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
11
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.
12
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.
13
Safety
Safety Warnings
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.
WARNING
UNDER
10
14
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.
15
Safety
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive
under certain conditions.
• Never allow a child to refuel or handle
gasoline.
• 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.
Exposure to Exhaust
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.
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.
16
Safety
Safety Warnings
Failure to Inspect Before Operating
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.
Protective Apparel
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.
17
Safety
Safety Warnings
Carrying a Passenger
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.
Using Alcohol or Drugs
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.
18
Safety
Safety Warnings
Operating on Pavement
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 on Public Roads
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.
19
Safety
Safety Warnings
Operating at Excessive Speeds
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.
Physical Control of the ATV
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.
20
Safety
Safety Warnings
Turning Improperly
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.
Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.
Jumps and Stunts
Attempting wheelies, jumps and other stunts
increases the risk of an accident or overturn.
Never attempt wheelies, jumps, or other stunts.
Avoid exhibition driving.
21
Safety
Safety Warnings
Improper Hill Climbing
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 82.
Operating on Steep Hills
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°
22
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 85.
• 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.
23
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 84.
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 86.
24
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 86.
25
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.
26
Safety
Safety Warnings
Operating in Unfamiliar Terrain
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.
Improper Tire Maintenance
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 79.
Before shifting into reverse gear, always check
for obstacles or people behind the ATV. When it’s
safe to proceed, back slowly.
27
Safety
Safety Warnings
Improper Vehicle Modifications
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. Your POLARIS dealer can
assist.
Operating Over Obstacles
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.
28
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.
29
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.
30
Safety
Safety Warnings
Operating on Frozen Bodies of Water
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.
Operating a Damaged ATV
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.
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.
Physical Skills
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.
Hot Exhaust 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.
31
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
32
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.
33
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.
34
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.
35
Safety
Safety Labels and Locations
Tire Pressure Warning (OUTLAW)
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)
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)
36
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.
37
Safety
Safety Labels and Locations
SPORTSMAN 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)
38
Safety
Safety Labels and Locations
Clutch Cover Warning
WARNING
NO STEP
• Moving parts hazard under belt-clutch guard. To
prevent serious injury, do not operate vehicle with
guard removed.
• Do not touch clutch cover, cover may become hot.
• Do not modify engine or clutch. Doing so can cause
part failure, possible imbalance, and excessive
engine RPM which can result in serious injury or
death.
39
Youth
Section
40
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 120.
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 158 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.
41
Know Your ATV
Before you have an adult start the engine for you for the first time, let's learn about the
controls 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.
3. Throttle Control
1. Engine Stop Switch
2. Horn Button
42
Know Your ATV
4. Shift Lever - The shift lever is on the
right side of the ATV. Read about how
to use the shift lever on page 62.
4. Shift Lever
43
Know Your ATV
5. Gas Cap - The gas cap has to be taken
off when an adult puts gas in your ATV.
Never take the gas cap off. Always
make sure it’s tightly closed.
Always have an adult put gas in your
ATV. Never try to do it yourself.
6. 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.
5. Gas Cap
6. Seat Latch
44
Know Your ATV
7. 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. Start Button - Use this button to start the engine when you’re ready to drive.
7. Rear Brakes
7. Front Brakes
8. Start Button
45
Know Your ATV
9. Ignition Switch - The ignition switch key must be turned on before pushing the start
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.
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.
10. Tether
Switch
9. Ignition
Switch
OUTLAW
SPORTSMAN
10. Tether
Switch
9. Ignition
Switch
46
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.
47
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.
48
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.
49
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
stopping the engine all three ways.
50
Riding Rules
Now you’re ready to learn about riding your POLARIS ATV. There are some things you can
do and there are some things you must never do. Rules are very important when you’re
driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.
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.
51
Riding Rules
ŹAlways wear the right kind of clothing and safety gear
when riding your ATV.
Helmet: Your helmet is very important for safe riding. A
helmet can prevent a severe head injury.
Eye Protection: Always wear shatterproof goggles or a
helmet face shield, and always keep them clean so you 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.
Boots: Wear sturdy over-the-ankle boots to keep your feet
dry. Boots will also protect your feet and ankles from
scrapes and scratches.
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.
Helmet
Eye Protection
Gloves
Over-the-Ankle
Boots
Long Pants
Long
Sleeves
52
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.
53
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
dangerous!
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.
54
Respect your ATV;
respect your environment;
and you will earn
the respect of everyone.
Enjoy riding your new POLARIS ATV!
55
Adult
Section
56
Vehicle Identification Numbers
Record your ATV’s identification
numbers and key number in the spaces
provided. 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.
Vehicle Model Number: ____________________________________________________________________
Frame VIN:______________________________________________________________________________
Engine Serial Number:_____________________________________________________________________
Key Number (on the key): __________________________________________________________________
Engine Serial Number
VIN
57
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.
OUTLAW
SPORTSMAN
58
Features and Controls
Engine Stop Switch
The engine will not start or run when the stop
switch is down, in the OFF position. Its
purpose 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.
Stop Switch
Start Button
Horn
59
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 on the left handlebar control.
Follow the Starting the Engine procedure beginning on page 74.
60
Features and Controls
Throttle Controls
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 or other qualified person for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in an accident if the
throttle lever sticks during operation. Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
The throttle release switch limits engine speed in the event of a throttle system malfunction.
Modifications to the throttle release switch could result in failure to perform as designed, which could
result in an accident. Do not attempt to modify the throttle control 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.
WARNING
61
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 a throttle release
switch, 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, engine speed will be limited to
idle speed.
NOTE: Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please
see your POLARIS dealer or other qualified service facility for adjustment.
Throttle
Lever
62
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 or other qualified person if you experience
any shifting problems.
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.
F
N
R
Shift
Lever
63
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.
Rear Brakes
Front Brakes
64
Features and Controls
Brakes
Parking Brake
1. Squeeze the left brake lever.
2. Push the parking brake lock down to lock
the brake lever in place.
3. 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.
Locked
Not Locked
65
Features and Controls
Lights
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 Description
Neutral Transmission is in neutral.
Reverse Transmission is in reverse.
Low Fuel The ATV can operate 7-10 miles (11-16
km) before the tank is completely empty.
Check
Engine
A flashing light indicates an overheated
engine. The system will automatically
reduce engine power. A solid light indicates
an EFI-related fault has occurred. Do not
operate the ATV. Serious engine damage
could result. Your POLARIS dealer can
assist.
OUTLAW
SPORTSMAN
Neutral
Reverse
Low
Fuel
Check
Engine
Neutral
Reverse
Low Fuel
Check
Engine
66
Features and Controls
Fuel System
Gas Cap
The fuel tank filler cap is located directly below the
handlebars.
Use unleaded gasoline with a minimum pump octane
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 158 for
fuel tank capacity.
Gas Cap
67
Operation
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 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.
Perform 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.
WARNING
68
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. See page 107. Add the recommended oil as needed to maintain the
oil level in the safe operating range.
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.
69
Operation
Break-in Period
5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride
inspection checklist. See page 70.
6. Perform the following maintenance at 10 hours or one month.
Item At 10 Hours or One Month
(End of Break-In Period)
See
Page
Engine oil change Perform break-in oil change 108
Oil pre-filter screen Clean filter with oil change 108
Transmission oil Perform break-in oil change 110
Drive chain Adjust and lubricate 131
Valve clearance See your dealer or other qualified person for inspection
and adjustment
--
70
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 Page
Brake system / lever travel Ensure proper operation 123, 127
Front suspension Inspect, lubricate if necessary 104
Rear suspension Inspect, lubricate if necessary 104
Steering Ensure free operation, lubricate if necessary 128, 130
Tires Check condition and pressure 137
Wheels / fasteners Inspect, ensure fastener tightness; check that
axle nuts are secured by cotter pins
139, 140
Fuel and oil Check and fill as needed 15, 66
71
Operation
Pre-Ride Inspection
Pre-Ride Checklist
Item Remarks Page
Throttle Check for proper operation 47, 60, 61
Engine stop switch Check for proper function 58
Daytime running lights (if equipped) Check for proper operation 143
Brakelight Check for proper operation 141
Air filter, pre-filter Inspect, clean or replace 134
Drive chain Check condition and slack; refer to drive
chain adjustment
131
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 10
72
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.
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.
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
determining the weight you are adding
to the vehicle, include the weight of the
operator, accessories and loads on the
racks (if equipped). The combined
weight of these items must not exceed
the maximum weight capacity.
73
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
handlebars 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
qualified 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
components. Always keep combustible
materials away from the exhaust
system.
13. Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use.
74
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. Sit on the vehicle. Attach the tether strap to the ATV and to your wrist.
4. Push the engine stop switch up to the ON position.
75
Operation
Starting the Engine
5. Turn the ignition key to ON.
6. Squeeze the rear brake lever and press the start button. The rear brake lever must be
engaged or the engine won’t start.
7. 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.
76
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.
77
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.
78
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.
79
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.
80
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.
81
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
82
Operation
Driving Uphill
Braking and handling are greatly affected when
operating in hilly terrain. Improper procedure
could cause loss of control or overturn.
Whenever 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
83
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
dismounting of the vehicle.
84
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!
85
Operation
Driving Downhill
When driving downhill, follow these
precautions:
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
traveling downhill can cause loss of
control.
5. Apply the front and rear brakes at the
same time, and very slightly, to aid in
slowing.
86
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.
87
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)
88
Operation
Parking on a Hill or Incline
Avoid parking on a hill or incline if
possible. 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
illustration.
89
Operation
Driving Over Obstacles
Follow these precautions when operating over
obstacles:
1. Always check for obstacles before
operating 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
obstacles, such as rocks or fallen trees.
90
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
91
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 96.
Engine oil, gearcase oil 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, service is required before starting the engine. Your POLARIS dealer can provide this
service. If it's impossible to bring the vehicle in before starting the engine, perform the
service outlined on page 114, and take the vehicle in for service at the first opportunity.
92
Operation
Hauling Cargo
The SPORTSMAN was designed with racks to carry small loads. Read and follow all of the
instructions for hauling cargo on the following pages.
Never carry cargo on the OUTLAW.
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
tipover.
• Slow down. Allow more space for stopping
the ATV when hauling cargo.
WARNING
2/3 1/3
93
Operation
Hauling Cargo
• Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section
beginning on page 158.
• 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.
94
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
standard 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
chamber by the intake system. All exhaust gases exit through the exhaust system.
95
Emission Control Systems
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel
delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
The emissions label is located on the right front frame support.
The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all
manufacturer 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.
96
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 183.
Tool Kit
97
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. Equivalent parts may be used for emissions-related service.
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
98
Maintenance
Periodic Maintenance Chart
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 or other qualified person perform these services.
Maintenance Chart Key
Symbol Description
Ź 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
components.
D Have an authorized POLARIS dealer or other qualified person perform these services.
99
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
Steering -- Daily -- Check each day before operating
the vehicle. Make adjustments as
needed. See the Pre-Ride Check-
list.
70
Front suspension -- Daily --
Rear suspension -- Daily --
Tires -- Daily --
Brake lever travel -- Daily --
Brake system -- Daily --
Wheels/fasteners -- Daily --
Frame fasteners -- Daily --
Engine oil level -- Daily --
Air filter, pre-filter & main
element
-- Daily -- Inspect; clean often; replace as
needed
134
Air box sediment tube -- Daily -- Drain deposits when visible --
Daytime running lights/tail
lamp
-- Daily -- Check operation; apply dielectric
grease if replacing
141
143
100
Maintenance
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
Drive chain -- Daily -- Inspect daily; adjust and lubricate
if needed
131
CVT housing (if equipped) -- Weekly -- Drain water as needed, check
often if operating in wet conditions
117
Break-in Maintenance After first 10 hours of operation Perform break-in maintenance 67
Ź
D
Brake lever travel/brake
freeplay
10 Monthly 100 (160) Inspect regularly 123
127
Spark plug 10 Monthly 100 (160) Clean; check condition; adjust
gap; replace as needed
112
Fuel System 20 Monthly -- Inspect; cycle key to pressurize
fuel pump; check lines and fittings
for leaks and abrasion
--
101
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
Battery 20 Monthly 200 (320) Check terminals; clean; test 144
Ź Engine oil change 30 6 M 300 (480) Drain and change the oil 108
Ź Transmission oil 40 12 M 400 (640) Drain and change the oil 110
Ź Oil pre-filter screen 40 12 M 400 (640) Clean filter at every oil change;
clean annually if ATV is operated
less than 10 hours
108
Ź General lubrication 50 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
--
D Valve clearance 50 3 M 500 (800 Check clearance; see your dealer
for adjustments
--
D Throttle cable/release
switch
50 6 M 500 (800) Inspect; adjust; lubricate; replace
if necessary
--
Throttle body intake duct 50 6 M 500 (800) Inspect duct for proper sealing/air
leaks
--
102
Maintenance
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer or other qualified person perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
D Drive belt 50 6 M 500 (800) See your POLARIS dealer --
Ź
D
Brake pad wear 50 6 M 500 (800) See your POLARIS dealer --
D Fuel System 100 12 M 1000 (1600) Cycle key to pressurize fuel pump;
check for leaks at fill cap, fuel
lines/rail and fuel pump; replace
lines every two years
--
Ź Engine mounts 100 12 M 1000 (1600) Inspect --
Exhaust muffler/pipe 100 12 M 1000 (1600) Inspect --
D Ignition timing 100 12 M 1000 (1600) Inspect --
103
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
Ź Wiring 100 12 M 1000 (1600) Inspect for wear, routing, security;
apply dielectric grease to connec-
tors subjected to water, mud, etc.
--
D Clutches (drive and driven) 100 12 M 1000 (1600) Inspect; clean; replace worn parts --
D Front wheel bearings 100 12 M 1000 (1600) Inspect; replace as needed --
Spark arrester 300 36 M 3000 (4800) Clean out 118
D Toe adjustment -- Inspect periodically; adjust when
parts are replaced
128
104
Maintenance
Lubrication Guide
Ź Perform these procedures more often for vehicles subjected to severe use.
Item Lube Method
Engine Oil PS-4 Extreme Duty
10W-50 4-Cycle Oil
See page 106.
Gearcase (Transmission)
Oil Level
AGL Gearcase Lubricant &
Transmission Fluid
See page 110.
Drive Chain POLARIS Chain Lube or SAE 80/90 See page 131.
Ź Front Suspension
(A-Arm)
POLARIS All Season Grease or
grease conforming to NLGI No. 2
Inspect; tighten fasteners;
grease (also after washing ATV
or driving in water).
105
Maintenance
Lubrication Guide
Grease Points
Grease Points
106
Maintenance
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 96. 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 162 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.
107
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.
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
immediately.
5. Add the recommended oil as needed.
6. Reinstall the dipstick.
Dipstick
Full
Add Oil
{
Safe Range
108
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.
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.
109
Maintenance
Engine Oil Change
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.
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 158 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
dipstick.
16. Dispose of used oil properly.
110
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 96. POLARIS recommends
the use of AGL Gearcase Lubricant &
Transmission Fluid. See page 162 for the part
numbers of POLARIS products.
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.
Fill Plug
Drain Plug
111
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 110 11.8 oz. (350 ml)
SPORTSMAN 110 11.8 oz. (350 ml)
112
Maintenance
Spark Plugs
Refer to the specifications section beginning on page 158 for spark plug and gap
specifications.
NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use
POLARIS-recommended spark plugs or their equivalent.
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.
113
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 overheating, caused by use of an
improper spark plug or incorrect throttle body adjustments.
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 or incorrect throttle body
adjustments.
Spark Plug Change
1. Remove the spark plug cap. Using the special wrench provided in the tool pouch, rotate
the spark plug counter-clockwise to remove it.
2. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).
114
Maintenance
Cylinder Head Torque
Have your dealer or other qualified person 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. Take the
vehicle in for service before starting the engine. Your POLARIS dealer can provide this
service. If this is not possible, follow the vehicle immersion inspection and drying
procedures outlined below. This procedure 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. Check the air box for any water and dry it if water is present.
3. Remove the spark plug.
115
Maintenance
Vehicle Immersion
4. Turn the engine over several times using the electric start.
5. Dry the spark plug and reinstall it, or replace it with a new plug.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or
not. Your POLARIS dealer can provide the required service.
8. If water has been ingested into the transmission, follow the procedure on page 117 for
drying the CVT.
116
Maintenance
Constant Variable Transmission (CVT) System
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 POLARIS dealer or other qualified person for service and repair assistance.
• This CVT system is intended for use on POLARIS products only. Do not install it in any other
product.
• Always make sure the CVT housing is securely in place during operation.
WARNING
117
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
bottom 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. Your vehicle requires service as soon as possible. See your POLARIS dealer or other
qualified service facility for service.
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.
118
Maintenance
Spark Arrester
To remove accumulated carbon, clean the spark arrester at the intervals recommended in the
Periodic Maintenance Chart beginning on page 96.
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
sufficiently before proceeding.
• Wear eye protection and gloves.
• Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
WARNING
119
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
compressed 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
120
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 Y-6+ models and 15 MPH or less for the
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.
This vehicle has an adjustable speed control system that controls engine RPM and speed of
the vehicle. The speed limiting device may be adjusted by supervising adults when they
determine that their child is capable of safely handling additional speed.
Per ANSI / SVIA-1-2010 (sec. 6.1) the unrestricted top speed is 15 MPH or less for the Y-6+
models and 30 MPH or less for the Y-10+ models.
121
Maintenance
Speed Control System
Throttle Stop Speed Control System
Use the following procedure to control how far
the throttle opens.
1. Loosen the jam nut.
2. Turn the screw inward to reduce speed or
outward to increase speed.
3. Tighten the jam nut after adjusting.
Jam Nut
Screw
122
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)
123
Maintenance
Brake Freeplay
Check (measure) the freeplay of the
front and rear brakes at the intervals
recommended in the Periodic
Maintenance Chart beginning on page
96. If the freeplay isn’t at specification,
adjust the freeplay as outlined on the
following pages.
Brake Freeplay Specifications
Front Brake Rear Brake
.08"-.12" (2-3 mm) .08"-.12" (2-3 mm)
Measure Freeplay
124
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.
5. When you begin to feel a slight drag
in wheel rotation, loosen the adjuster
nut one full turn.
Front Brake
Adjuster Nuts
125
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 123.
10. Carefully lower the vehicle to the ground.
126
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
rotation, 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 123.
8. Carefully lower the vehicle to the ground.
Rear Brake
Wing Nut
127
Maintenance
Brake Lever Travel
Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart
beginning on page 96. 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.
Component Total Lever Travel
Front brake lever 1 3/4" (45 mm)
Rear brake lever 2 1/2" (65 mm)
Measure
Lever
Travel
128
Maintenance
Toe Alignment
Use the following procedure to check the toe
alignment of the vehicle. The recommended toe
alignment is 1/8" to 1/4" (3-6 mm) toe out.
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 or other
qualified service facility.
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.
String
Stand
2
1
129
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
measurement 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.
130
Maintenance
Steering Inspection
Check the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are
found, see your POLARIS dealer or other qualified service facility before operating the
vehicle.
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
131
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
96. Lubricate more often under severe use, such as in dirty or wet conditions. See page 162
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.
132
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.
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 133.
Strap
Chain
Tensioner
133
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
134
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.
Support ScreenCoverClips Foam Filter
135
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.
136
Maintenance
Handlebar Adjustment
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 or
other qualified service person 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).
WARNING
Bolts
137
Maintenance
Tires
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.
WARNING
138
Maintenance
Tire Tread Depth
Always replace tires when tread depth is
worn to 1/8" (3 mm) or less.
Wheel Removal
1. Stop the engine and lock the parking brake.
2. Loosen the wheel bolts slightly.
3. Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.
4. Remove the wheel bolts and remove the
wheel.
1/8" (3 mm)
Wheel
Bolts
139
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).
140
Maintenance
Axle and Wheel Nuts
Do not service axle nuts that have a cotter pin installed. Your POLARIS dealer can assist.
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 or other qualified
service facility.
141
Maintenance
Tail Light Lamp Replacement
If the brakelight doesn’t work, the lamp may
need to be replaced.
1. Remove the two screws securing the lens
cover. Remove the lens cover.
2. Remove the lamp and replace it with a
new recommended lamp.
3. Test the light for proper operation.
4. Reinstall the lens cover.
Screws
Cover
Lamp
142
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.
143
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 cover (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
position 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 cover (OUTLAW only).
144
Maintenance
Battery
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.
WARNING
145
Maintenance
Battery
Battery Removal
1. Remove the battery hold-down strap.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable next.
4. Lift the battery out of the ATV.
146
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.
147
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.
148
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.
149
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
replacement.
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.
150
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
vehicle.
• 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.
151
Maintenance
Storage
Exterior
Make necessary repairs and clean the vehicle as recommended. See page 147.
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.
152
Maintenance
Storage
Stabilize the Fuel
1. Fill the fuel tank with the recommended fuel.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent
fuel treatments or stabilizers. Follow the instructions on the container for the
recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel
and removes carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the
entire fuel delivery system.
153
Maintenance
Storage
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean. Follow the instructions on the
container. Start the engine. Allow it to idle for several minutes so the Carbon Clean
reaches the injectors. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To access the plug hole,
use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-
measured amount of oil.
3. Reinstall the spark plug. Torque to specification. See page 113.
4. Apply dielectric grease to the inside of the spark plug cap. Do not reinstall the cap onto
the plug at this step.
154
Maintenance
Storage
Fog the Engine
5. Turn the engine over several times. Oil will be forced in and around the piston rings and
ring lands, coating the cylinder with a protective film of fresh oil.
6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should
be completely drained of gasoline.
7. Reinstall the spark plug cap to the spark plug.
155
Maintenance
Storage
Engine Oil
Change the oil. See page 108.
Air Filter / Air Box
Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the
sediment tube.
Fluid Levels
Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart
beginning on page 96.
• Transmission Oil
• Engine Oil
156
Maintenance
Storage
Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic
Maintenance Chart beginning on page 96.
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.
157
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.
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.
Step 3
Tubes
Step 3 Step 4
158
Specifications
OUTLAW 110
Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg)
Dry Weight 270 lbs. (122.4 kg)
Length/Width/Height 61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm)
Wheel Base 41.5" (105 cm)
Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame
Engine type 4-Stroke
Displacement 111cc
Cooling Air Cooled
Bore x Stroke 61 mm x 57.8 mm
Alternator Output 80 watts
Compression Ratio 9.5:1
Lubrication Wet Sump
Oil Capacity 30 oz. (900 ml)
Fuel Capacity 1.7 gallons (6.4 liters)
Fuel Reserve Capacity .23 gallons (.86 liters)
Starting System Electric
159
Specifications
OUTLAW 110
Fuel System Electronic fuel injection
Throttle Body Size 22 mm
Ignition System CDI
Ignition Timing 32° +/- 2° @ 5000 RPM
Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm
Drive System Automatic CVT
Final Drive Chain
Front Suspension Single A-arm with 5" (12.7 cm) of travel
Rear Suspension Swing arm with 6" (15.2 cm) of travel
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi/20.7 kPa)
Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kPa)
Brake Light Standard
Daytime Running Lights Standard
160
Specifications
SPORTSMAN 110
Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg)
Dry Weight 289 lbs. (131 kg)
Length/Width/Height 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm)
Wheel Base 41.5" (105 cm)
Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame
Engine type 4-Stroke
Displacement 111cc
Cooling Air Cooled
Bore x Stroke 61 mm x 57.8 mm
Alternator Output 80 watts
Compression Ratio 9.5:1
Lubrication Wet Sump
Oil Capacity 30 oz. (900 ml)
Fuel Capacity 2 gallons (7.7 liters)
Fuel Reserve Capacity .22 gallons (.85 liters)
Starting System Electric
161
Specifications
SPORTSMAN 110
Fuel System Electronic fuel injection
Throttle Body Size 22 mm
Ignition System CDI
Ignition Timing 32° +/- 2° @ 5000 RPM
Spark Plug / Gap NGK CR6HSA / 0.6-0.7 mm
Drive System Automatic CVT
Final Drive Chain
Front Suspension Single A-arm with 5" (12.7 cm) of travel
Rear Suspension Swing arm with 6" (15.2 cm) of travel
Front Rack Capacity 15 lbs. (7 kg)
Rear Rack Capacity 30 lbs. (14 kg)
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi/20.7 kPa)
Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kPa)
Brake Light Standard
Daytime Running Lights Standard
162
POLARIS Products
Part Number Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)
2872348 Chain Lube, Aerosol
Grease
2871322 All Season Grease (3 oz./89 ml)
2871423 All Season Grease (14 oz./414 ml)
Miscellaneous Additives
2871326 Carbon Clean
163
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 Refuel, cycle key to ON position three times for 5
seconds each, then start
Clogged fuel filter Replace the filter
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plugs Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Your POLARIS dealer can assist.
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure Your POLARIS dealer can assist.
164
Troubleshooting
Engine Doesn’t Turn Over
Engine Pings or Knocks
Possible Cause Solution
Low battery voltage Recharge battery with .5 amp charger
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing Your POLARIS dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
165
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires Your POLARIS dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Throttle release switch malfunction Your POLARIS dealer can assist.
Other mechanical failure Your POLARIS dealer can assist.
166
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible Lean Fuel Mixture Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect fuel Replace with recommended fuel
167
Troubleshooting
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three times for 5
seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires Your POLARIS dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Throttle release switch malfunction Your POLARIS dealer can assist.
Other mechanical failure Your POLARIS dealer can assist.
Overheated engine Clean engine exterior. Your POLARIS dealer can
assist.
168
Warranty
LIMITED WARRANTY
POLARIS Industries 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 arrester 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.
169
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 racing, competition or 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.
170
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 • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components and fluids
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps • Spark plugs
•Filters •Sealants
• Lubricants • Coolants
• Bushings • Bearings
171
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.
172
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 CONSEQUENTIAL,
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.
173
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 Form 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.
174
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.
175
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.
176
Warranty
EXPORTED PRODUCTS
NOTICE
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
177
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 (1550 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.
178
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:
The following parts are also considered emission-related components for exhaust emissions:
• Air-induction system • Ignition system
• Fuel system • Exhaust gas recirculation systems
• Aftertreatment devices • Sensors
• Crankcase ventilation valves • Electronic control units
179
Warranty
U.S.A. EPA Emissions Limited Warranty
The following parts are considered emission-related components for evaporative emissions:
*As related to the evaporative emission control system.
• Fuel Tank • Vacuum Control Diaphragms*
• Fuel Cap • Control Cables*
• Fuel Line • Control Linkages*
• Fuel Line Fittings • Purge Valves
• Clamps* • Vapor Hoses
• Pressure Relief Valves* • Liquid/Vapor Separator
• Control Valves* • Carbon Canister
• Control Solenoids* • Canister Mounting Brackets
• Electronic Controls* • Carburetor Purge Port Connector
180
Warranty
U.S.A. EPA Emissions Limited Warranty
Emission-related components also include any other part whose only purpose is to reduce emissions or whose
failure will increase emissions without significantly degrading engine/equipment performance. 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.
181
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. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle.
POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. 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.
182
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 “B”
in the ninth position of the model number (e.g., R16RTE87B). 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
183
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
184
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
100 Hours
120 Hours
150 Hours
185
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
186
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
187
Index
A
Age Restrictions . . . . . . . . . . . . . . 13
Air Filter . . . . . . . . . . . . . . . . 134-135
Axle and Wheel Nuts . . . . . . . . . 140
B
Battery . . . . . . . . . . . . . . . . . 144-147
Installation and Connections 146
Removal. . . . . . . . . . . . . . . . 145
Storage. . . . . . . . . . . . . 147, 151
Boots . . . . . . . . . . . . . . . . . . . . . . . 11
Brake Adjustment, Front. . . . 124-125
Brake Adjustment, Rear . . . . . . . 126
Brake Freeplay . . . . . . . . . . . 123-126
Brake Freeplay Specifications . . 123
Brake Lever Travel . . . . . . . . . . . 127
Brake Levers . . . . . . . . . . . . . . . . . 44
Brake, Parking . . . . . . . . . . . . . . . 64
Brakes . . . . . . . . . . . . . . . . . . . . 63-64
Break-in Period . . . . . . . . . . . . 67- 69
C
Camber and Caster. . . . . . . . . . . . 130
Cleaning . . . . . . . . . . . . . . . . . . . . 147
Clothing . . . . . . . . . . . . . . . . . . . . . 11
Constant Variable Transmission . 116
Consumer Product Safety. . . . . . . . . 9
CVT Drying . . . . . . . . . . . . . . . . . 117
CVT System. . . . . . . . . . . . . . . . . 116
Cylinder Head Torque . . . . . . . . . 114
D
Daytime Running Lights . . . . . . . 143
Drive Chain . . . . . . . . . . . . . . . . . 131
Drive Chain Slack . . . . . . . . . . . . 132
Drive Chain Slack Adjustment . . 133
Driving Downhill. . . . . . . . . . . . . . 85
Driving in Reverse . . . . . . . . . . . . . 79
Driving on a Sidehill . . . . . . . . . . . 84
Driving on Slippery Surfaces. . 80-81
Driving Over Obstacles . . . . . . . . . 89
Driving Procedure . . . . . . . . . . . . . 77
Driving Through Water . . . . . . 90-91
Driving Uphill . . . . . . . . . . . . . 82-83
E
Emission Control Systems . . . . 94-95
Engine Fogging . . . . . . . . . . . 153-154
Engine Start Button. . . . . . . . . . . . 59
Engine Stop Switch. . . . . . . . . . . . 58
Equipment Modifications . . . . . . . 12
Exhaust, Exposure to. . . . . . . . . . . 15
Eye Protection . . . . . . . . . . . . . . . . 11
F
Fogging the Engine . . . . . . . 153, 154
Fuel Safety . . . . . . . . . . . . . . . . . . 15
Fuel Stabilizer . . . . . . . . . . . . . . . 152
Fuel System. . . . . . . . . . . . . . . . . . 66
G
Gas Cap . . . . . . . . . . . . . . . . . . 43, 66
Gasoline Handling. . . . . . . . . . . . . 15
Gearcase Capacity. . . . . . . . . . . . 111
Gloves . . . . . . . . . . . . . . . . . . . . . . 11
188
Index
H
Handlebar Adjustment . . . . . . . . . 136
Hauling Cargo . . . . . . . . . . . . . 92, 93
Helmet . . . . . . . . . . . . . . . . . . . . . . 10
Horn . . . . . . . . . . . . . . . . . . . . . . . . 59
Horn Button . . . . . . . . . . . . . . . . . . 41
I
Indicator Light . . . . . . . . . . . . . . . 142
Indicator Lights . . . . . . . . . . . . . . . 65
Instruction, Operating. . . . . . . . . . . 14
K
Key Switch . . . . . . . . . . . . . . . . . . . 57
K-Turn . . . . . . . . . . . . . . . . . . . . . . 86
L
Lamp Replacement
Daytime Running Lights. . . . 143
Indicator Light. . . . . . . . . . . . 142
Tail Light. . . . . . . . . . . . . . . . 141
Lights . . . . . . . . . . . . . . . . . . . . . . . 65
Lights, Daytime Running . . . . . . . 143
Lights, Indicator . . . . . . . . . . . . . . . 65
Lubrication Guide . . . . . . . . 104-105
M
Main Key Switch. . . . . . . . . . . . . . 57
Maintenance Chart. . . . . . . . . 96-103
Making Turns . . . . . . . . . . . . . . . . 78
Modifications. . . . . . . . . . . . . . . . . 12
O
Oil . . . . . . . . . . . . . . . . . . . . . . . . 106
Oil Change, Engine . . . . . . . 108-109
Oil Change, Transmission . . . . . . 111
Oil Check, Engine . . . . . . . . . . . . 107
Oil Check, Transmission . . . . . . . 110
Oil, Engine. . . . . . . . . . . . . . . . . . 106
Operator Restrictions. . . . . . . . . . . 13
P
Parking on a Hill or Incline. . . . . . 88
Periodic Maintenance Chart . 96-103
Polaris Products. . . . . . . . . . . . . . 162
Polishing . . . . . . . . . . . . . . . . . . . 150
Pre-Ride Inspection . . . . . . . . . 70-71
R
Restrictions, Age . . . . . . . . . . . . . . 13
Riding Gear . . . . . . . . . . . . . . . 10-11
S
Safe Operation Practices. . . . . . 72-73
Safety Labels and Locations. . . 32-38
Safety Training . . . . . . . . . . . . . . . 8-9
Safety Warnings . . . . . . . . . . . . 13-30
Safety Words and Symbols. . . . . . . . 6
Seat Latch . . . . . . . . . . . . . . . . . . . . 43
Severe Use . . . . . . . . . . . . . . . . . . . 97
Shift Lever . . . . . . . . . . . . . . . . 42, 62
Shock Spring Adjustment. . . . . . . 130
Sidehilling. . . . . . . . . . . . . . . . . . . . 84
Signal words . . . . . . . . . . . . . . . . . . . 6
Spark Arrester. . . . . . . . . . . . 118-119
Spark Plug Change . . . . . . . . . . . . 113
Spark Plugs. . . . . . . . . . . . . . 112-113
Specifications
OUTLAW 110. . . . . . . . 158-159
SPORTSMAN 110 . . . . 160-161
Speed Control System . . . . . 120-121
Start Button. . . . . . . . . . . . . . . . . . . 59
Starting the Engine . . . . . . . . . . 74-75
Steering Inspection . . . . . . . . . . . . 130
Stop Switch. . . . . . . . . . . . . . . . . . . 58
Stopping the ATV. . . . . . . . . . . . . . 46
Stopping the Engine . . . . . . . . . . . . 76
Storage . . . . . . . . . . . . . . . . . 151-156
189
Index
S
Switches
Engine Start Button . . . . . . . . 59
Engine Stop Switch . . . . . 41, 58
Horn Button . . . . . . . . . . . . . . 41
Ignition Switch. . . . . . . . . . . . 45
Main Key Switch . . . . . . . . . . 57
Tether Switch. . . . . . . . . . . . . 45
T
Tail Light . . . . . . . . . . . . . . . . . . 141
Tether Strap. . . . . . . . . . . . . . . . . . 45
Throttle . . . . . . . . . . . . . . . . . . . . . 60
Throttle Cable Adjustment . . . . . 122
Throttle Control . . . . . . . . . . . . . . 41
Throttle Lever . . . . . . . . . . . . . . . . 61
Tire Tread Depth. . . . . . . . . . . . . 138
Tires . . . . . . . . . . . . . . . . . . . . . . 137
Toe Alignment . . . . . . . . . . . 128-129
Transmission Oil. . . . . . . . . . 110-111
Transporting the ATV. . . . . . . . . 157
Turning Around on a Hill . . . . . 86-87
V
Vehicle Identification Numbers. . . 56
Vehicle Immersion. . . . . . . . 114-115
W
Warranty, Emissions . . . . . . 177-182
Washing the ATV . . . . . . . . . . . . 148
Wheel Hub Tightening. . . . . . . . . 140
Wheel Installation . . . . . . . . . . . . 139
Wheel Nuts. . . . . . . . . . . . . . . . . . 140
Wheel Removal . . . . . . . . . . . . . . 138
WARNING
Improper vehicle use can result in
SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
S without proper training or instruction
S at speeds too fast for your skills or the conditions
S on public roads - a collision can occur with
another vehicle
S with a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS:
S use proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
S avoid paved surfaces - pavement may
seriously affect handling and control
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9927393 Rev 0
Printed in Taiwan
