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.
1
Visit us at www.polarisindustries.com
2
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.
Copyright 2007 Polaris Sales 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 con-
tained within, whether whole or in part, is expressly prohibited.
Printed in USA
2008 Outlaw 90/Sportsman 90 ATV Owner's Manual
P/N 9921483
3
Welcome
Dear Parents:
We believe your children should have the opportunity to enjoy The Way Out experience
along with you. We've provided this owner's manual to assist you and your children in learn-
ing about safe operation and care of your new ATV. Please review the information in this
manual with any child who may operate the ATV. Help your children learn to operate the
ATV with safety as a top priority. Help them also learn to show respect for our environment
and for the rights of others while operating the ATV.
Children differ in skills, physical abilities and judgement. Some children may not be able to
operate an ATV safely. Always supervise your child's use of the ATV, and permit continued
use only if you determine that your child has the ability and maturity to operate the ATV
safely. Never allow a child to operate the ATV without adult supervision.
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 various intervals. For
safe and enjoyable operation of the vehicle, be sure to follow all of the instructions and rec-
ommendations in this manual. If you have any questions about the ATV, contact a Polaris
dealer for assistance.
4
Welcome
Dear Children:
Before you ride your new Polaris ATV, there are some important things that you need to
know. 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.
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.
As the driver of the ATV, you must learn how to keep yourself and those around you safe
while you're riding. So read your manual, and then enjoy riding your new Polaris ATV!
5
Table of Contents
Safety. . . . . . . . . . . . . . . . . . . . . . 6
Youth Section . . . . . . . . . . . . . . 17
Know Your ATV . . . . . . . . . . . 18
Pre-Ride Check. . . . . . . . . . . 25
Riding Rules . . . . . . . . . . . . . 28
Adult Section. . . . . . . . . . . . . . . 33
Safety Decals . . . . . . . . . . . . 34
Driver Warnings. . . . . . . . . . . 43
Vehicle ID Numbers. . . . . . . . 66
Features and Controls . . . . . . 67
Break-in Period . . . . . . . . . . . 83
Pre-Ride Inspections . . . . . . . 85
Starting the Engine . . . . . . . . 88
Stopping the Engine . . . . . . . 91
Driving Safely . . . . . . . . . . . . 92
Emission Control . . . . . . . . . 112
Maintenance . . . . . . . . . . . . 114
Specifications . . . . . . . . . . . 178
Polaris Products . . . . . . . . . 182
Troubleshooting . . . . . . . . . . 184
Warranty . . . . . . . . . . . . . . . 190
Maintenance Log . . . . . . . . . 198
Index. . . . . . . . . . . . . . . . . . . . . 202
6
Safety
Understand the Warnings
Always follow the age guidelines for your ATV. Never allow a younger child to ride on or
drive the ATV. Make sure all operators have completed an approved ATV safety training
course such as the SVIA RiderCourse
sm
and understand all warnings and the owner's manual
before driving the ATV.
Know Your ATV Before Riding
Parents must help their children learn the proper and safe way to ride an ATV. Read the
owner's manual with your children before starting the engine for the first time, and review it
with them periodically afterwards.
7
Safety
Safety Training
ATV safety training is a top priority for Polaris. When you purchased your new ATV, your
dealer instructed you on the authorized ATV RiderCourse
sm
available to you and your eligi-
ble family members. This training is included in the purchase price of your ATV. Polaris
strongly encourages you and your age eligible family members who will be riding the ATV
to take the ATV RiderCourse
sm
.
In addition, you were provided with printed material and a video or DVD that instructs oper-
ators on safe operating procedures. You should review this information with your child on a
regular basis.
If you purchased a used Polaris ATV, you can take the ATV RiderCourse
sm
by calling ATV
Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a
used Polaris ATV will be charged for this training.
8
Safety
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, on your vehicle or in this
manual, alerts you to the potential for injury.
WARNING
The safety alert warning indicates a potential
hazard that may result in serious injury or death.
CAUTION
The safety alert caution indicates a potential haz-
ard that may result in minor injury or damage to
the vehicle.
CAUTION
A caution indicates a situation that may result in
damage to the vehicle.
NOTE:
A note will alert you to important information or
instructions.
9
Safety
WARNING
Failure to follow the warnings 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 precau-
tions.
Read and understand the owner's manual and all warnings before operating a Polaris ATV.
10
Safety
• Read this manual and all labels carefully.
Follow all operating procedures.
• Never operate an ATV without proper
instruction. Take a training course. Pur-
chasers of a new Polaris ATV and age eli-
gible family members are entitled to take
the ATV RiderCourse
sm
. Contact ATV
Enrollment Express at (800) 887-2887 or
visit www.atvsafety.org for information
on enrollment in the ATV RiderCourse
sm
.
• Always follow the age guidelines for
your vehicle: Y-12 90cc models are
designed for children not less than 12
years of age and Y-6 50cc models are
designed for children not less than 6 years
of age. No child under the age of 16
should ride any ATV designed and sold
for an adult.
• 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 such as the ATV
RiderCourse
sm
.
• Always avoid operating an ATV on any
paved surfaces, including sidewalks,
driveways, parking lots and streets.
• Never operate an ATV on any public
street, road or highway, including dirt or
gravel roads.
• Always be sure there are no obstacles or
people behind your ATV when operating
in reverse. Drive slowly and avoid turn-
ing at sharp angles in reverse.
11
Safety
• Never operate an ATV without wearing
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.
• Never consume alcohol or drugs before
or while operating this ATV.
• Never operate at excessive speeds.
Always travel at a speed which is proper
for the terrain, visibility and operating
conditions, and your experience.
• Never attempt jumps or other stunts.
• Never tow or pull an object behind the
ATV.
• Always inspect your ATV each time you
use it to make sure it is in safe operating
condition. Always follow the inspection
and maintenance procedures and sched-
ules described in this manual.
• Always keep both hands on the handle-
bars and both feet on the footrests of the
ATV during operation.
• Always go slowly and be extra careful
when operating on unfamiliar terrain.
Always be alert to changing terrain con-
ditions when operating the ATV.
• Never operate on excessively rough, slip-
pery or loose terrain.
12
Safety
• Always follow proper procedures for
turning as described in this manual. Prac-
tice turning at low speeds before attempt-
ing to turn at faster speeds. Do not turn at
excessive speed.
• Always have the ATV checked by an
authorized Polaris dealer if it has been
involved in an accident.
• Never operate the ATV on hills too steep
for the ATV or for your abilities. Practice
on smaller hills before attempting larger
hills.
• Always follow proper procedures for
climbing hills as described in this manual.
Check the terrain carefully before you
start up any hill. Never climb hills with
excessively slippery or loose surfaces.
Shift your weight forward. Never open
the throttle suddenly or make sudden gear
changes. Never go over the top of any hill
at high speed.
• Always follow proper procedures for
going down hills and for braking on hills
as described in this manual. Check the
terrain carefully before you start down
any hill. Shift your weight backward.
Never go down a hill at high speed. Avoid
going down a hill at an angle which
would cause the vehicle to lean sharply to
one side. Go straight down the hill where
possible.
13
Safety
• Always follow proper procedures for
crossing the side of a hill as described in
this manual. Avoid hills with excessively
slippery or loose surfaces. Shift your
weight to the uphill side of the ATV.
Never attempt to turn the ATV around on
any hill until you have mastered the turn-
ing technique described in this manual on
level ground. Avoid crossing the side of a
steep hill.
• Always use proper procedures if you stall
or roll backwards when climbing a hill.
To avoid stalling, maintain a steady speed
when climbing a hill. If you stall or roll
backwards, follow the special procedure
for braking described in this manual. Dis-
mount on the uphill side or to either side
if pointed straight uphill. Turn the ATV
around and remount, following the proce-
dure described in this manual.
• Always be careful of skidding or sliding.
On slippery surfaces, such as ice, go
slowly and be very cautious in order to
reduce the chance of skidding or sliding
out of control.
14
Safety
• Always check for obstacles before oper-
ating in a new area. Never attempt to
operate over large obstacles, such as
rocks or fallen trees. Always follow
proper procedures when operating over
obstacles as described in this manual.
• Avoid operating the ATV through deep or
fast flowing water. If you cannot avoid
water which exceeds the recommended
maximum depth (see page 106), go
slowly, balance your weight carefully
avoiding sudden movements, maintain a
slow and steady forward motion, do not
make sudden turns or stops, and do not
make sudden throttle changes.
• Wet brakes may have reduced stopping
ability. Test your brakes after leaving
water. If necessary apply them lightly
several times to let friction dry out the
pads.
• Always use the size and type tires speci-
fied in this manual. Always maintain
proper tire pressure as described in this
manual.
• Never modify an ATV through improper
installation or use of accessories.
• Never exceed the stated load capacity for
an ATV.
• Always remove the ignition key when the
vehicle is not in use to prevent unautho-
rized use or accidental starting.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product
Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
15
Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general public. Therefore, we
strongly recommend that consumers do not install on a Polaris ATV any equipment that may
increase the speed or power of the vehicle, or make any other modifications to the vehicle for
these purposes. Any modifications to the original equipment of the vehicle create a substan-
tial safety hazard and increase the risk of bodily injury.
The warranty on your Polaris ATV is terminated if any equipment has been added to the
vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
NOTE: The addition of certain accessories may change the handling characteristics of the ATV. Use
only Polaris-approved accessories, and familiarize yourself with their function and effect on
the ATV.
16
17
Youth
Section
18
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 142.
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 178 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.
19
Know Your ATV
Before you have an adult start the engine for you for the first time, let's learn about the con-
trols on your new ATV.
1. Engine Stop Switch - When the engine is running, push this button down to shut the
engine off quickly. The button must be up before you can start the engine again.
2. Horn Button - Press the horn button to sound the horn.
3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to
go forward. Always make sure the throttle control does not stick before you drive your
ATV. Read more about it on page 25.
3. Throttle Control
1. Engine Stop Switch
2. Horn Button
20
Know Your ATV
4. Kick-Start Lever - If your battery is
too weak to start your ATV, you can
push down on the kick-start lever with
your foot to start the engine. Have an
adult show you how it works. Read
more about how to use the kick-start on
page 82.
5. Shift Lever - The shift lever is on the
right side of your ATV. Read about how
to use the shift lever on page 72.
5. Shift Lever
4. Kick-Start Lever
21
Know Your ATV
6. Gas Cap - The gas cap has to be taken
off when an adult puts gas in your ATV.
Never take the gas cap off. Always
make sure it's tightly closed.
Always have an adult put gas in your
ATV. Never try to do it yourself.
7. Seat Latch - The seat latch is under the
left edge of the seat. Reach under the
left rear fender and pull back on the
latch to remove the seat. To replace the
seat, set it in place and push down on
the seat above the latch. Always make
sure the seat is locked in place before
riding.
6. Gas Cap
7. Seat Latch
22
Know Your ATV
8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the
ATV. The left lever controls the rear brake. The right lever controls the front brake.
Always squeeze both brake levers at the same time.
Always squeeze both brake levers at the same time or you could lose control of the ATV and
be seriously injured. Always take your thumb off the throttle lever when you squeeze the
brake levers.
8. Rear Brakes
8. Front Brakes
23
Know Your ATV
9. Ignition Switch - The ignition switch key must be turned on before pushing the starter
button. You can also use this key to turn off the engine.
10. Tether Strap and Switch - The tether strap must always be attached snugly to your right
wrist and to your ATV every time you drive. If you fall off your ATV, the tether strap
will pull away from the switch and the engine will stop.
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
10. Tether Switch
9. Ignition Switch
OUTLAW
SPORTSMAN
24
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.
25
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.
n 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.
26
Pre-Ride Check
n 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.
n 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 78 of this manual.
Always have an adult put gas in your ATV. Never try to do it yourself.
27
Pre-Ride Check
n If you used the storage area under the seat, make sure the seat is locked in place.
n 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.
n 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 24 and review. Then have an adult help you start the engine. Practice stop-
ping the engine all three ways.
28
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.
X The 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.
29
Riding Rules
X Always 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 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
Boots
Long Pants
Long
Sleeves
30
Riding Rules
X Always attach the tether strap to your right wrist
and to the ATV before riding.
X Make sure you know where you're going to drive
before your ATV is started. Make sure the area is
safe all around your ATV.
X Your ATV is made for one person. Never carry a
passenger. A passenger will make the ATV
harder to drive. You may lose control and hurt
yourself and your passenger.
X Always drive your ATV while sitting down. Keep
both hands on the handlebars and keep both feet
on the footrests.
X Always 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.
X Never follow another ATV too closely. You need lots of time and space to stop your
ATV.
X Never tow or pull an object behind the ATV.
31
Riding Rules
X Never ride alone. An adult should always be watching you in case you need help.
Always drive within the sight of an adult.
X Never ride on public trails.
X Don'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.
X Don't ride at night. Your ATV doesn't have lights that are safe for driving in the dark.
X Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away
from them.
X Never ride on frozen water. You could get hurt or you could even die. All ice can be dan-
gerous!
X Ride 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.
X Always be a polite driver. (Don’t drive through the flower garden or over the little trees
you planted!)
X Always do your best to help take care of nature.
32
Respect your ATV;
respect your environment;
and you will earn
the respect of everyone.
Enjoy riding your new Polaris ATV!
33
Adult
Section
34
Safety Decals
Warning decals have been placed on the ATV for your protection. Read and follow the
instructions on each decal carefully. If any of the decals shown in this manual differ from the
decals on your ATV, always read and follow the instructions of the decals on the ATV.
If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a
replacement. Replacement safety decals are provided by Polaris at no charge. The part num-
ber is printed on the decal.
35
Safety Decals
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. IF
OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT.
+
36
Safety Decals
Age Warning
WARNING
• Kids under age 12 should NEVER operate this ATV.
Kids under 12 have an increased chance of losing con-
trol, which could result in severe injury or death.
• Adult supervision is required.
• Make sure operators follow Owner's Manual and labels.
• Make sure operators watch the safety video or DVD
and complete the ATV RiderCourse
sm
.
• Never operate this ATV on HILLS steeper than 15
degrees 15
°. To prevent flipover on hilly terrain,
use throttle and brakes gradually.
• REVERSE operation can be dangerous even at low
speeds. Steering becomes difficult. To prevent flipover,
avoid sudden braking or sharp turns.
+
37
Safety Decals
Outlaw 90 Tire Pressure Warning
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING
can cause loss of control, resulting in SEVERE
INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7)
REAR 3 (20.7)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle
Weight) INCLUDING MACHINE, DRIVER AND
CARGO IS 453 LBS. (206 KG).
+
38
Safety Decals
Sportsman 90 Tire Pressure Warning
WARNING
IMPROPER TIRE PRESSURE OR OVERLOADING
can cause loss of control resulting in SEVERE
INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7)
REAR 3 (20.7)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle
Weight) INCLUDING MACHINE, DRIVER AND
CARGO IS 528 LBS. (240 KG).
Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carry-
ing tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be
centered, carried as low as possible, and firmly secured to the racks. With dual racks, load distri-
bution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Be
careful if load extends over the side of the rack.
Read Owner's Manual for more detailed loading information.
+
39
Safety Decals
No Passenger Warning
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting
in SEVERE INJURY or DEATH.
+
+
40
Safety Decals
Sportsman 90 Rack Warning
WARNING
DO NOT TOW WITH THIS VEHICLE.
Vehicle damage or tipover may result causing
severe injury or death.
Maximum Rack Loads: Front 15 lbs. (6.8 kg)
Rear 30 lbs. (13.6 kg)
+
+
41
Safety Decals
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 exces-
sive engine RPM which can result in serious injury
or death.
+
42
43
Driver Warnings
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 following hazards MUST be avoided at all times.
44
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV without proper instruction.
WHAT CAN HAPPEN
The risk of an accident is greatly increased if the operator does not know how to operate the ATV
properly in different situations and on different types of terrain.
HOW TO AVOID THE HAZARD
Beginning and inexperienced operators should complete the ATV RiderCourse
sm
offered by Polaris
through the SVIA. They should then regularly practice the skills learned in the course and the oper-
ating techniques described in the Owner's Manual.
For more information about the ATV RiderCourse
sm
contact ATV Enrollment Express at (800) 887-
2887 or visit www.atvsafety.org.
45
Driver Warnings
WARNING
POTENTIAL HAZARD
Failure to follow the age recommendations for this ATV.
WHAT CAN HAPPEN
Use by children of ATVs that are not recommended for their age can lead to severe injury or death of
the child.
Even though a child may be within the age group for which some ATVs are recommended, he or she
may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved
in a serious accident.
HOW TO AVOID THE HAZARD
Follow the age recommendations for this ATV.
46
Driver Warnings
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN HAPPEN
Carrying a passenger greatly reduces your ability to balance
and control this ATV.
Carrying a passenger could cause an accident, resulting in harm
to you and/or your passenger.
HOW TO AVOID THE HAZARD
Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as
needed during operation. It is not intended for passengers.
47
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV on paved surfaces, including sidewalks,
paths, parking lots and driveways.
WHAT CAN HAPPEN
The ATV tires are designed for off-road use. Paved surfaces
may seriously affect handling and control of the ATV, and
may cause the vehicle to go out of control.
HOW TO AVOID THE HAZARD
Avoid operating the ATV on pavement whenever possible. If
you must ride on a paved surface, go slowly and do not
make sudden turns or stops.
48
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV on public streets, roads or highways.
WHAT CAN HAPPEN
You can collide with another vehicle.
HOW TO AVOID THE HAZARD
Never operate this ATV on any paved or unpaved public
street, road or highway.
In many states it is illegal to operate ATVs on public
streets, roads and highways.
49
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing protective gear.
WHAT CAN HAPPEN
Operating without an approved helmet increases the risk
of a severe head injury or death in the event of an acci-
dent. Operating without eye protection and protective
clothing can also result in injury.
HOW TO AVOID THE HAZARD
Always wear an approved helmet that fits properly.
Always wear eye protection (goggles or face shield),
gloves, boots, long-sleeved shirt or jacket, and long
pants.
50
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming alcohol or drugs.
WHAT CAN HAPPEN
Your judgment could be seriously affected.
You may react more slowly.
Your balance and perception will be affected.
You could have an accident.
HOW TO AVOID THE HAZARD
Never consume alcohol or drugs before or while driving
this ATV.
51
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV at excessive speeds.
WHAT CAN HAPPEN
Increases your chances of losing control of
the ATV, which can result in an accident.
HOW TO AVOID THE HAZARD
Always travel at a speed which is proper for
the terrain, visibility and operating conditions;
and your experience.
WARNING
POTENTIAL HAZARD
Failure to inspect the ATV before operating.
Failure to properly maintain the ATV.
WHAT CAN HAPPEN
Increases the possibility of an accident or
equipment damage.
HOW TO AVOID THE HAZARD
Always inspect your ATV each time you use it
to make sure the ATV is in safe operating con-
dition. Always follow the inspection and main-
tenance procedures and schedules described
in the Owner's Manual.
52
Driver Warnings
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts.
WHAT CAN HAPPEN
Attempting stunts increases the chance of an accident,
including an overturn.
HOW TO AVOID THE HAZARD
Never attempt jumps, or other stunts. Avoid exhibition
driving (don't show off).
53
Driver Warnings
WARNING
POTENTIAL HAZARD
Removing hands from handlebars or feet from footrests during operation.
WHAT CAN HAPPEN
Removing even one hand or foot can make it harder to control the ATV or could cause you to lose
your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may touch
the rear wheels, which could injure you or cause an accident.
HOW TO AVOID THE HAZARD
Always keep both hands on the handlebars and both feet on the footrests of your ATV during opera-
tion.
54
Driver Warnings
WARNING
POTENTIAL HAZARD
Failure to use extra care when operating this ATV on
unfamiliar terrain.
WHAT CAN HAPPEN
You can come upon hidden rocks, bumps, or holes,
without enough time to react. This could cause the
ATV to overturn or go out of control.
HOW TO AVOID THE HAZARD
Go slowly and be extra careful when operating on
unfamiliar terrain.
Always be alert to changing terrain conditions when operating the ATV.
55
Driver Warnings
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating on exces-
sively rough, slippery or loose terrain.
WHAT CAN HAPPEN
Operating on excessively rough, slippery or loose terrain
could cause loss of traction or loss of control, which
could result in an accident or overturn.
HOW TO AVOID THE HAZARD
Do not operate on excessively rough, slippery or loose
terrain until you've learned and practiced the skills nec-
essary to control the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
56
Driver Warnings
WARNING
POTENTIAL HAZARD
Turning improperly.
WHAT CAN HAPPEN
Improper turns could cause loss of control
and lead to a collision or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for turning
as described in the owner's manual.
Practice turning at slow speeds before
attempting to turn at faster speeds.
Never turn at excessive speed.
WARNING
POTENTIAL HAZARD
Towing or pulling an object behind the ATV.
WHAT CAN HAPPEN
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.
HOW TO AVOID THE HAZARD
Never tow or pull an object behind the ATV.
57
Driver Warnings
WARNING
POTENTIAL HAZARD
Climbing hills improperly.
WHAT CAN HAPPEN
Improper hill climbing could cause loss of control or overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for climbing hills as
described in the Owner's Manual beginning on page 98.
Always check the terrain carefully before you start up any hill.
Never climb hills with excessively slippery or loose surfaces.
Shift your weight forward.
Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any
hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side
of the hill.
58
Driver Warnings
WARNING
POTENTIAL HAZARD
Going down a hill improperly.
WHAT CAN HAPPEN
Driving downhill improperly could cause loss of control or
ATV overturn.
HOW TO AVOID THE HAZARD
Always follow proper procedures for going down hills as
described in the Owner's Manual. See page 104.
NOTE: A special technique is required when braking as you go downhill.
Always check the terrain carefully before you start down any hill. Shift your weight backward. Never
go down a hill at high speed.
Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Go
straight down the hill when possible.
59
Driver Warnings
WARNING
POTENTIAL HAZARD
Improperly crossing hills and turning on hills.
WHAT CAN HAPPEN
Improperly crossing or turning as hills could cause loss of
control or overturn.
HOW TO AVOID THE HAZARD
Never try 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 102. Use extra
caution when turning on any hill. Avoid crossing the side of
a steep hill.
When crossing the side of a hill:
Always follow proper procedures as described in the owner's manual. Avoid hills with excessively
slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
60
Driver Warnings
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly dismounting while climb-
ing a hill.
WHAT CAN HAPPEN: The ATV could overturn and cause injury.
HOW TO AVOID THE HAZARD: Maintain steady speed when
climbing a hill.
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 you begin rolling backwards: 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 102.
61
Driver Warnings
WARNING
POTENTIAL HAZARD
Skidding or sliding.
WHAT CAN HAPPEN
Skidding or sliding can cause loss of control.
If the tires regain traction unexpectedly, the
ATV could overturn.
HOW TO AVOID THE HAZARD
On slippery surfaces such as ice, travel slowly
and use extra caution to reduce the chance of
skidding or sliding out of control.
WARNING
POTENTIAL HAZARD
Improperly operating over obstacles.
WHAT CAN HAPPEN
Operating over obstacles could cause loss of
control or overturn.
HOW TO AVOID THE HAZARD
Before operating in a new area, check for
obstacles.
Avoid operating over large obstacles such as
rocks and fallen trees when possible. If
unavoidable, use extreme caution and always
follow proper procedures as outlined in the
owner's manual.
62
Driver Warnings
WARNING
POTENTIAL HAZARD
Riding on frozen lakes and rivers.
WHAT CAN HAPPEN
Severe injury or death can result if the ATV
and/or the operator break through the ice.
HOW TO AVOID THE HAZARD
Never ride your ATV on a frozen body of
water.
WARNING
POTENTIAL HAZARD
Operating this ATV with improper tires, or with
improper or uneven tire pressure.
WHAT CAN HAPPEN
Use of improper tires, or operation of the ATV
with improper or uneven tire pressure, could
cause loss of control or accident.
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified
in the owner's manual for the ATV.
Always maintain proper tire pressure as
stated in the specifications section of the
owner's manual.
63
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN HAPPEN
Tires may float, causing loss of traction and loss of control, which could lead to an accident or over-
turn.
HOW TO AVOID THE HAZARD
Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that
exceeds the recommended maximum depth (see page 106), travel slowly, balance your weight
carefully, avoid sudden movements, and 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. Always test the brakes after leaving water. If neces-
sary, apply them several times to let friction dry out the pads.
64
Driver Warnings
WARNING
POTENTIAL HAZARD
Overloading the ATV.
WHAT CAN HAPPEN
Overloading the ATV could cause changes in
handling, which could lead to an accident.
HOW TO AVOID THE HAZARD
Never exceed the stated load capacity for this
ATV.
If equipped with racks, cargo should be prop-
erly distributed and securely attached.
WARNING
POTENTIAL HAZARD
Operating the ATV with improper modifica-
tions.
WHAT CAN HAPPEN
Improper installation of accessories or modifi-
cation of the ATV may cause changes in han-
dling which could lead to an accident.
HOW TO AVOID THE HAZARD
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.
65
Driver Warnings
WARNING
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 overturns and loss of control which
could result in severe injury or death. Do not
allow disabled persons to operate this vehicle.
WARNING
Damaged components can cause loss of con-
trol resulting in serious injury or death. After a
rollover or an accident, have a qualified ser-
vice dealer check the complete vehicle includ-
ing, but not limited to, brakes, throttle and
steering for possible damage.
WARNING
Hot components can cause serious burns. Do
not touch hot exhaust system components.
Hot components could cause a fire if exposed
to combustible materials such as dry grass
and weeds. 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.
WARNING
Leaving the keys in the ignition can lead to
unauthorized use of the vehicle resulting in
serious injury or death. Always remove the
ignition key when the vehicle is not in use.
66
Vehicle Identification Numbers
Record your ATV's identification num-
bers and key number in the spaces pro-
vided. Remove the spare key and store it
in a safe place. An ignition key can be
duplicated only by ordering a Polaris
key blank (using your key number) and
mating it with one of your existing keys.
The ignition switch must be replaced if
all keys are lost.
Vehicle Model Number: ____________________________________________________________________
Frame VIN:______________________________________________________________________________
Engine Serial Number: _____________________________________________________________________
Key Number (on the key): __________________________________________________________________
Engine Serial Number
VIN
67
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.
WARNING
Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury
or death. Always remove the ignition key when the vehicle is not in use.
Key
Key
OUTLAW SPORTSMAN
68
Features and Controls
Engine Stop Switch
The engine will not start or run when the stop
switch is down, in the OFF position. Its pur-
pose is to provide the operator with a quick
means of engine shutdown in case of stuck
throttle or other emergency.
NOTE: 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.
Choke Lever
Use the choke to start a cold engine. Push the choke lever to the left before starting the
engine. When the engine starts, gradually return the choke lever to the OFF position as the
engine warms up and runs smoothly.
Stop Switch
Choke Lever
Start Button
Horn
69
Features and Controls
Horn Button
Use the horn for emergencies and to let others know you’re near.
Engine Start Button
The start button is located slightly above the choke lever
1. Attach the tether strap securely to the vehicle and to the rider's right wrist.
2. Shift the transmission to neutral. The neutral light will come on when the lever is in neu-
tral. See page 77.
3. Turn the key to the ON position.
4. Lock the parking brake.
5. Push the engine stop switch up to the ON position.
6. Press the start button.
70
Features and Controls
Throttle Controls
WARNING
Operating an ATV with sticking or improperly operating throttle controls could cause an accident and
lead to severe injury or death.
Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your
dealer for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result in an accident if the
throttle lever sticks during operation. Always check the lever for free movement and return before
starting the engine. Also check occasionally during operation.
71
Features and Controls
Throttle Lever
Press the throttle lever toward the handlebar to
increase engine speed and vehicle movement.
Engine speed returns to idle when the lever is
released.
This ATV is equipped with an Electronic Throttle
Control (ETC), which is designed to reduce the
risk of a frozen or stuck throttle. If the throttle
cable should stick in an open position when the
operator releases the throttle lever, the engine will
stop and power to the rear wheels will cease.
WARNING
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction
and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after
market throttle mechanism.
Throttle
Lever
72
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 mov-
ing.
Maintaining shift linkage adjustment is
important to assure proper transmission
function. See your dealer if you experience
any shifting problems.
Shift Pattern
F: Forward Gear
N: Neutral
R: Reverse
F
N
R
Shift
Lever
73
Features and Controls
CAUTION
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.
Always place the transmission in gear with the parking brake applied and turn the vehicle off when-
ever the vehicle is left unattended.
74
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
75
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. To release the parking brake lock,
squeeze and release the brake
lever. The parking brake will
release automatically.
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
76
Features and Controls
Brakes
Parking Brake
1. Always shift the transmission to neutral and lock the parking brake before starting the
engine.
2. After the engine has warmed enough for operation, shift to the desired gear.
3. Release the parking brake and gently apply the throttle.
4. Always lock the parking brake whenever the vehicle is left unattended.
77
Features and Controls
Lights
Indicator Lights
Indicator lights on the ATV let
you know when your ATV is in
neutral or reverse.
WARNING
Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not
operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visi-
bility. This ATV is designed for off-road use only. Do not operate this ATV on streets or highways.
Neutral
Reverse
Reverse
Neutral
OUTLAW SPORTSMAN
78
Features and Controls
Fuel System
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• 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 per-
formed 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.
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes are poisonous
and can cause loss of consciousness or death in a short time.
• Turn the fuel valve off whenever the ATV is stored or parked. See page 81.
79
Features and Controls
Fuel System
WARNING
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.
80
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 of 87. Refer to the specifications sec-
tion beginning on page 178 for fuel tank capacity.
Gas Cap
81
Features and Controls
Fuel Valve
The fuel valve is located on the
left side of the ATV. It has three
settings.
OFF: For vehicle storage and
when transporting.
ON: For normal operation.
RES: For reserve supply if main
supply is exhausted.
NOTE:
The reserve setting allows
operation for approximately
7-10 miles (11-16 km).
Always refill the gas tank as
soon as possible after using
the main supply. Always
return the valve to the ON
position after refueling.
Sportsman 90
Fuel Valve
OFF RESON
Outlaw 90
Fuel Valve
82
Features and Controls
Kick-Start Lever
If the battery becomes too weak to start the engine, use the
kick-start lever to start the engine until the battery is serviced.
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Lock the parking brake.
4. Fold out the kick-start lever on the left side of the ATV.
NOTE: A 10/12mm wrench is provided in the tool kit for removing
or installing the lever. If not installed, make sure the rubber
cap is on the kick-start shaft to protect the rider. Store the
lever under the seat when it’s not installed.
5. Push the engine stop switch up to the ON position.
6. Turn the key to ON.
7. Place your foot on the kick-start, then thrust your heel
downward to crank the engine.
8. After the engine has started, fold the kick-start lever back into place.
Kick-Start Lever
83
Break-in Period
The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of
operation, or the time it takes to use the first two full tanks of gasoline. No single action on
your part is as important as following the procedures for a proper break-in. Careful treatment
of a new engine will result in more efficient performance and longer life for the engine. Per-
form the following procedures carefully.
CAUTION
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.
84
Break-in Period
1. Fill the fuel tank with gasoline. See page 78.
2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the
proper range. See page 125.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
4. Vary throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride
inspection checklist. See page 85.
6. Perform the following maintenance at the end of the break-in period.
Item Remarks
See
Page
Engine oil change Perform break-in oil change 126
Oil pre-filter screen Clean filter with oil change 127
Transmission oil Perform break-in oil change 130
Valve clearance See your dealer for inspection and adjustment --
85
Pre-Ride Inspection
WARNING
If a proper inspection is not done before each use, severe injury or death could result. Always
inspect the ATV before each use to ensure it's in proper operating condition.
Pre-Ride Checklist
Item Remarks Page
Brake system / lever travel Ensure proper operation 145, 149
Front suspension Inspect, lubricate if necessary 122
Rear suspension Inspect, lubricate if necessary 122
Steering Ensure free operation, lubricate if neces-
sary
150, 152
86
Pre-Ride Inspection
Pre-Ride Checklist
Item Remarks Page
Tires Check condition and pressure 159
Wheels / fasteners Inspect, ensure fastener tightness;
check that axle nuts are secured by cot-
ter pins
161, 162
Fuel and oil Check and fill as needed 78, 80
Throttle Check for proper operation 25, 70, 71
Engine stop switch Check for proper function 68
Daytime running lights (if equipped) Check for proper operation 165
Brakelight Check for proper operation 163
87
Pre-Ride Inspection
Pre-Ride Checklist
Item Remarks Page
Air filter, pre-filter Inspect, clean or replace 156
Drive chain Check condition and slack; refer to drive
chain adjustment
153
Frame nuts, bolts, fasteners Inspect, ensure tightness --
Loose or damaged components Visually inspect for any damaged com-
ponents or loose fasteners
--
Riding gear Wear helmet, goggles, protective cloth-
ing
92
88
Starting the Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness result-
ing in severe injury or death. Never run an engine in an enclosed area.
CAUTION
Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm
up for several minutes before operating.
89
Starting the Engine
1. Shift the transmission to neutral.
2. Lock the parking brake.
3. Turn the fuel valve on.
4. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist.
NOTE: The choke is fully on when the lever is pushed completely to the left. The choke is off when
the lever is pushed completely to the right. The choke can be adjusted gradually, depending
on how much choke is needed for starting.
5. If the engine is cold, use full choke by pushing the choke lever all the way to the left. A
warm engine will not require the use of the choke.
6. Push the engine stop switch up to the ON position.
7. Turn the ignition key to ON.
NOTE: Do not press the throttle while starting the engine.
90
Starting the Engine
8. Squeeze the rear brake lever and press the starter button.
NOTE: The rear brake lever must be engaged or the engine won't start.
9. Activate the starter for a maximum of five seconds, releasing the button when the engine
starts. If it doesn't start, release the starter, wait five seconds, then activate for another
five seconds. Repeat until the engine starts.
10. If the engine slows or stops, position the choke lever half way to allow proper engine
warm up. Vary the RPM slightly with the throttle to aid in warm up.
11. When the engine idles smoothly, push the choke lever all the way to the right.
91
Stopping the Engine
1. Release the throttle completely and brake to a complete stop.
2. Shift the transmission to neutral.
3. Stop the engine.
NOTE: 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.
NOTE: To avoid draining the battery, always turn the key to the OFF position when the engine is not
running.
4. Lock the parking brake.
WARNING
A rolling vehicle can cause property damage and serious injury. Always apply the parking brake
after stopping the engine.
92
Driving Safely
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 sur-
rounding the letter E, followed by the distinguishing
number of the country which has granted approval. The
approval number and serial number will also be dis-
played on the label.
Helmet
Eye
Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
93
Driving Safely
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-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-
pads and a jersey with shoulder pads provide the best protection.
94
Driving Safely
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.
95
Driving Safely
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.
NOTE: Practice making turns at slow speeds.
WARNING
Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious
injury. Avoid turning at sharp angles. Never turn at high speeds.
96
Driving Safely
Driving on Slippery Surfaces
WARNING
Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and
cause loss of control, accident, and serious injury or death.
Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution.
97
Driving Safely
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing
weather, follow these precautions:
1. Slow down when entering slippery areas.
2. Maintain a high level of alertness, reading
the trail and avoiding quick, sharp turns,
which can cause skids.
3. Correct a skid by turning the handlebars in
the direction of the skid and shifting your
body weight forward.
98
Driving Safely
Driving Uphill
WARNING
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could
cause loss of control or overturn and result in serious injury or death.
Avoid climbing steep hills (15
° maximum).
Use extreme caution when operating on hills, and follow proper operating procedures outlined in the
owner's manual.
99
Driving Safely
Driving Uphill
Whenever traveling uphill, follow these
precautions:
1. Always travel straight uphill.
2. Avoid steep hills (15
° maximum).
3. Keep both feet on the footrests.
4. Transfer your weight forward.
5. Proceed at a steady rate of speed and
throttle opening.
6. Remain alert and be prepared to take
emergency action. This may include
quick dismounting of the vehicle.
15° Maximum
100
Driving Safely
Driving Across Hillsides
WARNING
Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting
in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures
as outlined in the owner's manual.
101
Driving Safely
Driving Across Hillsides
Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you
do enter into a situation where sidehilling is necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your
upper body weight uphill while keep-
ing your feet on the footrests.
3. Steer slightly into the hill to maintain
direction.
NOTE: If the vehicle begins to tip, quickly turn
the front wheel downhill, if possible, or
dismount on the uphill side immedi-
ately!
102
Driving Safely
Turning Around on a Hill
If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can
be used when it's necessary to turn around while climbing a hill is the K-turn:
1. Stop and lock the parking brake while maintaining 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.
WARNING
Improper hill climbing procedures could cause loss of control or overturn and result in serious injury
or death.
Avoid climbing steep hills (15
° maximum).
Use extreme caution when operating on hills, and follow proper operating procedures outlined in the
owner's manual.
103
Driving Safely
Turning Around on a Hill
5. Staying uphill of the ATV, turn the handle-
bars full left.
6. While holding the brake, release the park-
ing 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.
7. Lock the parking brake and remount the
ATV from the uphill side, maintaining
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)
104
Driving Safely
Driving Downhill
Whenever descending a hill, follow these
precautions:
1. Drive directly downhill.
2. Transfer your weight to the rear of the
vehicle.
3. Slow down.
4. Apply the front and rear brakes at the
same time, and very slightly, to aid in
slowing.
WARNING
Excessive speed can cause loss of control
and lead to serious injury or death. Always
operate slowly when traveling downhill.
105
Driving Safely
Parking on a Hill or Incline
Avoid parking on a hill or incline if pos-
sible. If it's unavoidable, follow these
precautions:
1. Turn the engine off.
2. Lock the parking brake.
3. Always block the rear wheels on the
downhill side as shown in the illus-
tration.
4. Turn the fuel valve off.
106
Driving Safely
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 procedures when operating through water:
1. Determine water depths before driving through
water.
2. If crossing a stream, choose a crossing where
both banks have gradual inclines.
3. Proceed slowly, avoiding rocks and obstacles if
possible.
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.
Maximum Depth
107
Driving Safely
Driving Through Water
Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in
deeper water than recommended, it's critical to have it serviced as outlined in the mainte-
nance chart beginning on page 114. The following areas need special attention: engine oil,
gearcase oil, front and rear gearcases (if equipped) and all grease fittings.
CAUTION
Major engine damage can result from driving this ATV in deeper water than recommended. If your
vehicle becomes immersed or is operated in water that exceeds the bottom of the footrests, take it
to your dealer for service before starting the engine.
108
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the ter-
rain you're traveling on. Be constantly alert
for hazards such as logs, rocks and low hang-
ing branches.
WARNING
Severe injury or death can result if your vehicle
comes in contact with a hidden obstacle. Not
all obstacles are immediately visible. Travel
with caution in unfamiliar terrain.
109
Driving Safely
Driving in Reverse
Follow these guidelines when operating in reverse:
1. Back slowly.
2. Apply the brakes lightly for stopping.
3. Avoid turning at sharp angles.
4. Always avoid backing downhill.
5. Never open the throttle suddenly while backing.
6. Always look left, right and behind the ATV before backing.
WARNING
Failure to use caution when operating in reverse can result in serious injury or death. Before shifting
into reverse, always check for obstacles or people behind the vehicle and follow the reverse opera-
tion procedures outlined in this manual. Always back slowly.
110
Driving Safely
Hauling Cargo
The Sportsman 90 was designed with racks to carry small loads. Read and follow all of the
instructions for hauling cargo on the following pages. Never carry cargo on the Outlaw 90.
• 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
Hauling cargo improperly can may cause loss of control and result in serious injury or death. Always
carry cargo as instructed in safety decals and in the owner’s manual.
2/3 1/3
111
Driving Safely
Hauling Cargo
• Never exceed the weight capacities for the vehicle. Capacities are listed in the specifica-
tions section beginning on page 178.
• 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.
112
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 require-
ments.
Operation on Public Lands in the U.S.A.
Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance
with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arres-
tor 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 8343.
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.
113
Emission Control Systems
Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine design, including
factory-set fuel delivery and ignition. The engine and related components must be main-
tained at Polaris specifications to achieve optimal performance.
Engine idle speed is the only adjustment Polaris recommends that the operator perform. Any
other adjustments should be performed by an authorized Polaris dealer.
The emissions label is located on the clutch cover or engine case near the clutch box.
NOTE: The installation of devices that effectively increase exhaust emissions beyond their legal lim-
its 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 European directives 97/24/EC and 89/336/EEC.
114
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 198.
115
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.
NOTE: 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
116
Maintenance
Periodic Maintenance Chart
Maintenance Chart Key
X Perform these operations more often under severe use, such as in dirty or wet condi-
tions, to purge water or dirt contamination from grease fittings and other critical components.
E Emission-related service (Failure to conduct this maintenance will not void the emis-
sions warranty but may affect emissions.)
Q Dealer service item.
WARNING
Improperly performing the procedures marked with a Q could result in component failure and lead to
serious injury or death. Have an authorized Polaris dealer perform these services.
117
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
Q Steering -- Daily -- Check each day before operating
the vehicle. Make adjustments as
needed. See the Pre-Ride Check-
list.
85
X Front suspension -- Daily --
X Rear suspension -- Daily --
Tires -- Daily --
X Brake lever travel -- Daily --
Brake system -- Daily --
Wheels/fasteners -- Daily --
Frame fasteners -- Daily --
X Engine oil level -- Daily --
XE Air filter, pre-filter & main
element
-- Daily -- Inspect; clean often; replace as
needed
156
X Air box sediment tube -- Daily -- Drain deposits when visible --
Headlamp/tail lamp -- Daily -- Check operation; apply dielectric
grease if replacing
163
165
118
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer 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
153
CVT housing (if equipped) -- Weekly -- Drain water as needed, check
often if operating in wet conditions
137
Break-in Maintenance After first 10 hours of operation Perform break-in maintenance 83
XQ Brake lever travel/brake
freeplay
10 Monthly 100 (160) Inspect regularly 145
149
QE Spark plug 10 Monthly 100 (160) Clean; check condition; adjust
gap; replace as needed
132
Idle speed 10 Monthly 100 (160) Check; adjust as needed 141
QE Choke 10 Monthly 100 (160) Check for proper operation; see
your dealer for adjustments
119
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 166
X Engine oil change 30 6 M 300 (480) Drain and change the oil 126
X Transmission oil 40 12 M 400 (640) Drain and change the oil 130
X 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
127
X General lubrication 50 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
--
QE Valve clearance 50 3 M 500 (800 Check clearance; see your dealer
for adjustments
--
Carburetor float bowl 50 6 M 500 (800) Drain bowl periodically and prior
to storage
--
QE Throttle cable/ETC switch 50 6 M 500 (800) Inspect; adjust; lubricate; replace
if necessary
--
QE Choke cable 50 6 M 500 (800) Inspect; adjust; lubricate; replace
if necessary
--
120
Maintenance
Periodic Maintenance Chart
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
E Carburetor air intake
ducts/flange
50 6 M 500 (800) Check for proper sealing/air leaks --
Q Drive belt 50 6 M 500 (800) See your Polaris dealer --
XQ Brake pad wear 50 6 M 500 (800) See your Polaris dealer --
QE Fuel system 100 12 M 1000 (1600) Check for leaks at tank cap, lines,
fuel valve, filter, pump, carburetor;
replace lines every two years
--
QE Fuel filter 100 12 M 1000 (1600) Change filter 129
X Engine mounts 100 12 M 1000 (1600) Inspect --
Exhaust muffler/pipe 100 12 M 1000 (1600) Inspect --
Q Ignition timing 100 12 M 1000 (1600) Inspect --
121
Maintenance
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
See
Page
Hours Calendar Miles (Km)
X Wiring 100 12 M 1000 (1600) Inspect for wear, routing, security;
apply dielectric grease to connec-
tors subjected to water, mud, etc.
--
Q Clutches (drive and driven) 100 12 M 1000 (1600) Inspect; clean; replace worn parts --
Q Front wheel bearings 100 12 M 1000 (1600) Inspect; replace as needed --
Spark arrestor 300 36 M 3000 (4800) Clean out 138
Q Toe adjustment -- Inspect periodically; adjust when
parts are replaced
150
122
Maintenance
Lubrication Guide
XPerform these procedures more often for vehicles subjected to severe use
Item Lube Method
Engine Oil Polaris Synthetic Youth Oil
or Synthetic SAE 40
See page 124.
Gearcase (Transmission)
Oil Level
Premium AGL Synthetic
Gearcase Lube
See page 130.
Drive Chain Polaris Chain Lube or SAE 80/90 See page 153.
X Front Suspension
(A-Arm)
Polaris All Season Premium
Grease or grease conforming to
NLGI No. 2
Inspect; tighten fasteners;
grease (also after washing
ATV or driving in water).
123
Maintenance
Lubrication Guide
Grease Points
Grease Points
124
Maintenance
Engine Oil
Oil Recommendations
Always check and change the engine oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 114. Oil may need to be changed more frequently if Polaris oil is
not used. Do not use automotive oil. See page 182 for the part numbers of Polaris products.
Under These Operating Conditions Use This Recommended Oil
Outside air temperature is above 32
° F/0° C
Polaris Synthetic Youth Oil
(or Synthetic SAE40)
Outside air temperature is below 32
° F/0° C
Semi-Synthetic 20W-40
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the
recommended oil. Never substitute or mix oil brands.
125
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.
NOTE: 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
126
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 serious burns to skin. Do not allow hot oil to come into contact with skin.
127
Maintenance
Engine Oil Change
5. Place a drain pan under the engine crankcase.
6. Remove the pre-filter plug. Allow the oil to
drain completely.
7. Wash the oil pre-filter screen with solvent to
remove debris. Allow the screen to air dry.
8. Clean the pre-filter plug. Install a new sealing washer on the plug.
NOTE: 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.
128
Maintenance
Engine Oil Change
10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm).
11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill.
NOTE: See the specifications section beginning on page 178 for capacities.
12. Reinstall the dipstick.
13. Start the engine. Allow it to idle for one to two minutes.
14. Stop the engine and inspect for leaks.
15. Check the oil level. Add oil as needed to bring the level to the upper mark on the dip-
stick.
16. Dispose of used oil properly.
129
Maintenance
Fuel Filter
The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your
dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page
114. Do not attempt to clean the fuel filter.
130
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 114. Polaris recommends the
use of AGL Synthetic Gearcase Lubricant. See
page 182 for the part numbers of Polaris prod-
ucts.
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
131
Maintenance
Transmission Oil Change
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Place a drain pan under the gearcase.
4. Remove the drain plug. Allow the oil to drain completely.
5. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).
6. Add the recommended oil. Maintain the oil level at the bottom of the fill plug hole
threads.
7. Reinstall the fill plug. Check for leaks.
8. Dispose of used oil properly.
Gearcase Capacity
Outlaw 90 11.8 oz. (350 ml)
Sportsman 90 11.8 oz. (350 ml)
132
Maintenance
Spark Plugs
Refer to the specifications section beginning on page 178 for spark plug and gap specifica-
tions.
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
Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-rec-
ommended spark plugs.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective gloves when removing
a spark plug for inspection.
133
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.
NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an
improper spark plug or incorrect carburetor/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, improper use of the choke,
or incorrect carburetion adjustments.
Spark Plug Change
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclock-
wise to remove it.
3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).
134
Maintenance
Cylinder Head Torque
Have your dealer check the ATV cylinder head for proper torque at the first service, or after
25 hours.
Vehicle Immersion
If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined
below.
1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Turn the fuel valve off.
3. Check the air box for any water and dry it if water is present.
4. Remove the spark plug.
CAUTION
If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly
inspected. Take the vehicle to your dealer before starting the engine.
135
Maintenance
Vehicle Immersion
5. Loosen the carburetor drain screw.
6. Turn the engine over several times using the electric start.
7. Dry the spark plug and reinstall it, or replace it with a new
plug.
8. Tighten the carburetor drain screw.
9. Turn the fuel valve on.
10. Attempt to start the engine. If necessary, repeat the drying
procedure.
11. Take the ATV to your dealer for service as soon as possible,
whether you succeed in starting it or not.
NOTE: If water has been ingested into the transmission, follow the pro-
cedure on page 137 for drying the CVT.
Drain Screw
136
Maintenance
Constant Variable Transmission (CVT) System
WARNING
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the CVT system. Doing so may reduce its strength so that a failure
may occur at a high speed. The CVT system has been precision balanced. Any modification will
cause the system to be out of balance, creating vibration and additional loads on components.
The CVT system rotates at high speeds, creating large amounts of force on clutch components.
Extensive engineering and testing has been conducted to ensure the safety of this product. How-
ever, as the owner, you have the following responsibilities to make sure this system remains safe:
Always follow all recommended maintenance procedures. See your dealer as outlined in the
owner's manual.
This CVT system is intended for use on Polaris products only. Do not install it in any other product.
Always make sure the CVT housing is securely in place during operation.
137
Maintenance
CVT Drying
There may be some instances when water is accidently ingested into the CVT system. Use
the following instructions to dry it out before operating. The drain plug is located on the bot-
tom of the CVT cover.
1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug.
2. Shift the transmission to neutral.
3. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-
dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.
4. Allow the engine RPM to settle to idle speed.
5. Test for belt slippage. If the belt slips, repeat the process.
6. Take the vehicle to your dealer for service as soon as possible.
CAUTION
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.
138
Maintenance
Spark Arrestor
To remove accumulated carbon, clean the spark arrestor at the intervals recommended in the
Periodic Maintenance Chart beginning on page 114.
WARNING
Failure to heed these warnings could result in serious injury or death.
Do not perform service on the spark arrestor while the system is hot. Allow components to cool suf-
ficiently before proceeding.
Wear eye protection and gloves.
Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas.
139
Maintenance
Spark Arrestor
1. Remove the six bolts and remove the arres-
tor from the end of the muffler.
2. Use a non-synthetic brush to clean the
arrestor screen. A synthetic brush may
melt if components are warm. If necessary,
blow debris from the screen with com-
pressed air.
3. Inspect the screen for wear and damage.
Replace the arrestor if damage is found.
4. Reinstall the arrestor.
5. Torque the bolts to 7 ft. lbs. (9.5 Nm).
Arrestor Screen
140
Maintenance
Carburetor
IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at alti-
tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4
degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly
rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m)
increase in elevation. Although this power cannot be regained, adjustments to the carburetor
and drive system can be made to allow more efficient operation. Optional jets, available from
your Polaris dealer, are required for operation above 6,000 feet and temperatures below +40
degrees F. (4 degrees C.).
NOTE: Continuous operation of the engine without proper jetting when required can cause poor per-
formance, overheating or engine damage. See your Polaris dealer for more information about
jetting the ATV for conditions in your area.
141
Maintenance
Carburetor
If the engine idle speed is not satisfactory, and all other conditions are favorable, the carbure-
tor can be adjusted.
1. Start the engine.
2. Lock the parking brake.
3. Allow the engine to run for approximately five minutes.
4. Adjust the carburetor idle screw either in or out until the desired idle RPM is reached.
Turning the screw in (clockwise) will raise RPM. Turning the screw out (counterclock-
wise) will lower RPM.
142
Maintenance
Speed Control System
Per ANSI / SVIA-1-2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed of
youth models is restricted to under 10 MPH for the 50cc models and under 15 MPH for the
90cc models.
The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the
consumer's request, remove or adjust any speed limiting devices.
Your Polaris ATV has an adjustable throttle limiting screw. Speed limiting devices may be
adjusted/removed only by consumers when they determine that their child is capable of han-
dling the additional speed.
Per ANSI / SVIA-1-2001 (sec. 6.2) the unrestricted top speed is less than 15 MPH for the
50cc models and less than 30 MPH for the 90cc models.
143
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
144
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)
145
Maintenance
Brake Freeplay
Check (measure) the freeplay of the
front and rear brakes at the intervals rec-
ommended in the Periodic Maintenance
Chart beginning on page 114. If the
freeplay isn’t at specification, adjust the
freeplay as outlined on the following
pages.
Brake Freeplay Specifications
Model Front Brake Rear Brake
90cc Models .08”-.12" (2-3 mm) .08”-.12" (2-3 mm)
Measure Freeplay
146
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
147
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 145.
10. Carefully lower the vehicle to the ground.
148
Maintenance
Brake Freeplay
Rear Brake Adjustment
1. Position the vehicle on a level surface.
2. Shift the transmission to neutral.
3. Elevate the rear of the vehicle by placing a suitable
stand under the frame. The rear tires should be
slightly off the ground.
4. While rotating the rear wheels, tighten the rear brake
wing nut at the rear brake drum.
5. When you begin to feel a slight drag in wheel rota-
tion, loosen the wing nut one full turn.
6. Verify that the left hand brake functions correctly.
7. Verify that brake lever freeplay is at specification.
See page 145.
8. Carefully lower the vehicle to the ground.
Rear Brake
Wing Nut
149
Maintenance
Brake Lever Travel
Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart
beginning on page 114. 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
150
Maintenance
To e A l i g n m e n t
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.
1. Set the handlebars in a straight-ahead position.
NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. The frog
should always point straight back from the steering post.
2. Place stands in front of the vehicle, perpendicular to the rear tires.
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.
151
Maintenance
Toe Alignment
3. Tie an elastic string around the stands, making
sure the string just touches the side surface of
the rear tires on each side of the vehicle and
goes around the stands in front of the vehicle.
4. Measure the distance from the string to the rim
at the front and rear of the front rim. Rear mea-
surement should be 1/16" - 1/8" (2-3 mm)
more than the front measurement.
NOTE: If you discover improper alignment, see your
Polaris dealer for service.
Stands
Measure
to rim
152
Maintenance
Steering Inspection
Check the steering assembly periodically for loose nuts and bolts. If any are found, have
your dealer tighten them before operating the ATV.
Camber and Caster
The camber and caster are non-adjustable.
Shock Spring Adjustment
The front and rear shock absorber springs are adjustable
to increase or decrease spring tension. Rotate the
adjuster either clockwise or counter-clockwise to make
adjustments.
Adjuster
153
Maintenance
Drive Chain
Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the gen-
eral lubrication interval specified in the Periodic Maintenance Chart beginning on page 114.
Lubricate more often under severe use, such as in dirty or wet conditions. See page 182 for
the part numbers of Polaris products.
CAUTION
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.
CAUTION
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 specifica-
tions.
154
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 155.
Strap
Chain
Tensioner
155
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).
5. Tighten the four rear housing mount bolts to 43
ft. lbs. (60 Nm).
CAUTION
Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud.
Housing
Mount
Bolts
Chain Adjuster
156
Maintenance
Air Filter
1. Remove the seat. See page 21.
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
157
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.
CAUTION
Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear
and severe damage to the engine.
158
Maintenance
Handlebar Adjustment
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
Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts
can cause limited steering or loosening of the handlebars, resulting in loss of control and possible
serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris
dealer for service.
Bolts
159
Maintenance
Tires
WARNING
Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly
installed tires will affect vehicle handling and could cause an accident resulting in serious injury or
death.
Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual.
Always use original equipment size and type when replacing tires.
Make sure the wheels are installed properly.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.
160
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
161
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).
162
Maintenance
Axle and Wheel Nuts
All nuts with a cotter pin installed must be service by an authorized Polaris dealer.
Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical component operations.
All service must be performed by your authorized Polaris dealer.
163
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
L
amp
164
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.
165
Maintenance
Daytime Running Lights Lamp Replacement (if equipped)
If the daytime running lights do not operate, replace the lamps. Polaris recommends that you
install replacement lamps obtained from your authorized Polaris dealer.
1. Remove the front cab (Outlaw only).
2. Disconnect the lights from the harness.
3. Remove the rubber cover from the back of the light assembly.
4. Press the lamp retainer inward and turn it counter-clockwise to remove it. Note the posi-
tion of the lamp positioning tab, then carefully pull the lamp out.
5. Install the new lamp. Make sure the filament is horizontal.
6. Reinstall the lamp retainer. Press the retainer inward and turn it clockwise about 1/4 turn.
7. Start the engine to make sure the lights come on. If the lights do not operate, see your
Polaris dealer for service.
8. Reinstall the rubber cover, and reconnect the lights to the harness.
9. Reinstall the front cab (Outlaw only).
166
Maintenance
Battery
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.
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious
injury or death. When removing the battery, always disconnect the negative (black) cable first. When
reinstalling the battery, always connect the negative (black) cable last.
167
Maintenance
Battery
Battery Removal
1. Disconnect the hold-down straps securing the electrical box and battery in position.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable next.
4. Lift the battery out of the ATV.
168
Maintenance
Battery
Battery Installation and Connections
1. Set the battery in its holder.
2. Connect and tighten the red (positive) cable first.
3. Connect and tighten the black (negative) cable last.
4. Attach the hold-down strap.
5. Verify that cables are properly routed.
NOTE: When installing a new battery, make sure it's fully charged prior to its initial use. 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.
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.
169
Maintenance
Cleaning
Keeping your ATV clean will not only improve its appearance but it can also extend the life
of various components.
CAUTION
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.
170
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.
171
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
NOTE: 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.
172
Maintenance
Polishing
Polaris recommends the use of common household aerosol furniture polish for polishing the
finish on your Polaris vehicle. Follow the instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the finish of your vehi-
cle.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and
pads may contain dirt particles that will scratch the finish.
173
Maintenance
Storage
Exterior
Make necessary repairs and clean the vehicle as recommended. See page 169.
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.
174
Maintenance
Storage
Stabilize the Fuel
Polaris Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the
combustion chamber and the exhaust ports. It also prevents bacterial growth and promotes
better starting after the storage period.
1. Fill the fuel tank.
2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instruc-
tions on the container for the recommended amount.
NOTE: Carbon clean will also reduce the possibility of bacterial growth in the fuel system.
3. Start the engine and allow it to run for 15-20 minutes so the stabilizer can disperse
through the fuel in the tank and carburetor.
4. Stop the engine.
5. Turn the fuel valve off.
6. Drain the carburetor bowl.
175
Maintenance
Storage
Engine Oil
Change the oil. See page 126.
Air Filter / Air Box
Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sedi-
ment tube.
Fluid Levels
Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart
beginning on page 114.
• Transmission Oil
•Engine Oil
•Brake Fluid
176
Maintenance
Storage
Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-
tenance Chart beginning on page 114.
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.
NOTE: Do not use plastic or coated materials. They do not allow enough ventilation to prevent con-
densation, and may promote corrosion and oxidation.
177
Maintenance
Transporting the ATV
Follow these procedures when transporting the ATV.
1. Stop the engine.
2. Place the transmission in gear.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap and seat.
5. Turn the fuel valve off.
6. 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 the unit.
Accessories
Polaris has a wide range of accessories available for your ATV. Please see your Polaris
dealer.
178
Specifications
Outlaw 90
Rider Capacity/Maximum Weight 1 Rider/170 lbs. (77 kg)
Displacement 89cc
Cooling Air Cooled
Engine type 4-Stroke
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 Electric with kick-start backup
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
179
Specifications
Outlaw 90
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi)
Rear Tires 18 x 9.5 - 8 (3 psi)
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
Brake Light Standard
Daytime Running Lights Standard
180
Specifications
Sportsman 90
Rider Capacity/Maximum Weight 1 Rider/170 lbs. (77 kg)
Displacement 89cc
Cooling Air Cooled
Engine type 4-Stroke
Lubrication Wet Sump
Oil Capacity 30 oz. (900 ml)
Fuel Capacity 2 gallons (7.7 liters)
Fuel Reserve Capacity .22 gallons (.85 liters)
Starting Electric with kick-start backup
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
181
Specifications
Sportsman 90
Front Rack Capacity 15 lbs. (6.8 kg)
Rear Rack Capacity 30 lbs. (13.6 kg)
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front Tires 19 x 7 - 8 (3 psi)
Rear Tires 18 x 9.5 - 8 (3 psi)
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
Brake Light Standard
Daytime Running Lights Standard
182
Polaris Products
Part Number Description
Engine Lubricant
2876248 Synthetic Youth Oil (qt/.95 l)
2876249 Synthetic Youth Oil (gal/3.8 l)
2872175 Semi-Synthetic 20W-40 Oil (qt/.95 l)
2872176 Semi-Synthetic 20W-40 Oil (gal/3.8 l)
2870791 Fogging Oil, Aerosol
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lubricant (qt/.95 l)
2872348 Chain Lube, Aerosol
183
Polaris Products
Part Number Description
Grease
2871322 All Season Premium Grease (3 oz./89 ml)
2871423 All Season Premium Grease (14 oz./414 ml)
Miscellaneous Additives
2871326 Carbon Clean Plus
184
Troubleshooting
See your Polaris dealer if you're unable to identify solutions using the following charts.
Engine Turns Over, Fails to Start
Possible Cause Solution
Out of fuel Turn the fuel valve to reserve, refuel
Clogged fuel valve or filter Inspect and clean or replace
Water is present in fuel Drain the fuel system and refuel
Fuel valve is turned off Turn the fuel valve on
Old or non-recommended fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect plug(s), replace if necessary
No spark to spark plug Inspect plug(s), verify stop switch is on
Crankcase filled with water or fuel Immediately see your Polaris dealer
Overuse of choke Inspect, clean and/or replace spark plugs
Clogged fuel filter Replace the filter
Low battery voltage Recharge battery with .5 amp charger
Mechanical failure See your Polaris dealer
185
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 See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
186
Troubleshooting
Engine Backfires
Possible Cause Solution
Weak spark from spark plugs Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with new fuel
Incorrectly installed spark plug wires See your Polaris dealer
Incorrect ignition timing See your Polaris dealer
Mechanical failure See your Polaris dealer
Exhaust system leak See your Polaris dealer
187
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 See your Polaris dealer
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 with .5 amp charger
Kinked or plugged fuel vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
188
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
Low octane fuel Replace with recommended fuel
Clogged fuel filter Replace filter
Incorrect jetting See your Polaris dealer
Possible Rich Fuel Mixture Cause Solution
Overuse of choke Inspect, clean and/or replace spark plugs
Fuel is very high octane Replace with lower octane fuel
Incorrect jetting See your Polaris dealer
189
Troubleshooting
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn the fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Overuse of choke Inspect, clean and/or replace spark plugs
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your Polaris dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge battery with .5 amp charger
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Electronic throttle control malfunction See your Polaris dealer
Other mechanical failure See your Polaris dealer
190
Warranty
LIMITED WARRANTY
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all
components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also
gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts
and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty
begins on the date of purchase. This warranty is transferable to another consumer during the warranty period
through a Polaris dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris
within ten days. 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 the warranty
entitlement. If you have not signed the original registration and received the “customer copy”, please contact your
dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGIS-
TERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV 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.
191
Warranty
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship.
This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war-
ranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained,
used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur
during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this war-
ranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery mate-
rial, corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond
Polaris' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with
the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replace-
ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR-
RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS
OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHER-
WISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied
warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.
192
Warranty
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO
THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER 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 to you if inconsistent with controlling state law.
193
Warranty
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs.
When requesting warranty service you must present your copy of the Warranty Registration form to the dealer.
(THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris
suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform
warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance
they will contact the appropriate personnel at Polaris.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.
Recommended Lubricants
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris
engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.
194
Warranty
EXPORTED VEHICLES
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-
LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING
DEALER'S AUTHORIZED LOCATION.
This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers
may not give authorization for export. You should consult an authorized dealer to determine this vehicle's war-
ranty or service bulletin coverage if you have any questions.
This policy does not apply to vehicles registered to government officials or military personnel on assignment out-
side the country of the selling dealer's authorized location.
This policy does not apply to Safety Recalls.
How to Get Service
In the country where your vehicle 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 vehicle was purchased, Warranty or Service Bulletin repairs may be requested
from any authorized Polaris dealer who sells the same line as your vehicle.
Outside the country where your vehicle was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased, you should take your
vehicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the sell-
ing dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be
authorized to perform the warranty repair.
195
Warranty
EXPORTED VEHICLES
How to Get 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. Vehicles importation rules vary considerably from country to country. You
may be required to present documentation of your move to Polaris Industries in order to continue your warranty
coverage. You may also be required to obtain documentation from Polaris Industries in order to register your
vehicle in your new country.
If Purchased From A Private Party:
If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally
purchased, all warranty coverage will be denied.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce-
dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
(Vehicles registered to Government officials or military personnel on assignment outside of the country where the
vehicle was purchased will continue to be covered by the basic warranty.)
For questions call Polaris Customer Assistance:
United States: 1-888-704-5290
Canada: 1-204-925-7100
196
Warranty
U.S.A. EPA Emissions Limited Warranty
This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to
the Polaris standard limited warranty for this vehicle.
Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with
the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from
meeting these requirements.
The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur-
chaser and ends 30 months (2.5 years) after that date.
This emission-related warranty covers components whose failure would increase an engine's emissions, including
electronic controls, fuel injection, exhaust-gas recirculation, aftertreatment, or any other system utilized in this
vehicle to control emissions. Replacing or repairing other components not covered by this emissions warranty or
the standard warranty is the responsibility of the owner; including the parts, labor and other costs associated with
recommended maintenance.
197
Warranty
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or
replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM-
ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-
QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER ARISING OUT OF EXPRESS
OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHER-
WISE.
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.
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 any engine that has been used in racing com-
petition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explo-
sions or other similar causes beyond the control of Polaris.
If you have any questions regarding your warranty rights and responsibilities, you should contact the Polaris War-
ranty Department at 1-888-704-5290.
198
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
199
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
100 Hours
120 Hours
150 Hours
200
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
201
Maintenance Log
DATE SERVICE
INTERVAL
TECHNICIAN SERVICE PERFORMED / COMMENTS
202
Index
A
Accessories. . . . . . . . . . . . . . . . . . 177
Age Warning . . . . . . . . . . . . . . . . . 36
Air Filter. . . . . . . . . . . . . . . . 156-157
Axle and Wheel Nuts . . . . . . . . . . 162
B
Battery
Installation/Connections . . . 168
Removal . . . . . . . . . . . . . . . 167
Storage. . . . . . . . . . . . . 168, 173
Boots. . . . . . . . . . . . . . . . . . . . . . . . 93
Brake Adjustment, Front . . . 146-147
Brake Adjustment, Rear . . . . . . . . 148
Brake Freeplay . . . . . . . . . . . 145-148
Brake Freeplay Specifications . . . 145
Brake Lever Travel. . . . . . . . . . . . 149
Brake Levers . . . . . . . . . . . . . . . . . 22
Brake, Parking . . . . . . . . . . . . . 75-76
Brakes. . . . . . . . . . . . . . . . . . . . 74-76
Break-in Period . . . . . . . . . . . . 83-84
C
Camber and Caster . . . . . . . . . . . 152
Carburetor . . . . . . . . . . . . . . 140-141
Choke Lever . . . . . . . . . . . . . . . . . 68
Cleaning. . . . . . . . . . . . . . . . . . . . 169
Clothing . . . . . . . . . . . . . . . . . . . . . 93
Clutch Cover Warning. . . . . . . . . . 41
Constant Variable Transmission . 136
CVT Drying. . . . . . . . . . . . . . . . . 137
CVT System . . . . . . . . . . . . . . . . 136
Cylinder Head Torque . . . . . . . . . 134
D
Daytime Running Lights . . . . . . . 165
Drive Chain . . . . . . . . . . . . . . . . . 153
Drive Chain Slack . . . . . . . . . . . . 154
Drive Chain Slack Adjustment . . 155
Driving Across Hillsides . . . 100-101
Driving Downhill . . . . . . . . . . . . 104
Driving in Reverse. . . . . . . . . . . . 109
Driving on Slippery Surfaces . 96-97
Driving Over Obstacles . . . . . . . . 108
Driving Procedure . . . . . . . . . . . . . 94
Driving Through Water. . . . 106-107
Driving Uphill . . . . . . . . . . . . . 98-99
E
Electronic Throttle Control. . . . . . . 71
Emission Control Systems . . 112-113
Engine Start Button . . . . . . . . . . . . 69
Engine Stop Switch . . . . . . . . . . . . 68
Equipment Modifications . . . . . . . . 15
Eye Protection. . . . . . . . . . . . . . . . . 93
F
Fuel Filter . . . . . . . . . . . . . . . . . . . 129
Fuel Stabilizer. . . . . . . . . . . . . . . . 174
Fuel System . . . . . . . . . . . . . . . 78-80
Fuel Valve. . . . . . . . . . . . . . . . . . . . 81
G
Gas Cap. . . . . . . . . . . . . . . . . . . 21, 80
Gearcase Capacity . . . . . . . . . . . . 131
Gloves. . . . . . . . . . . . . . . . . . . . . . . 93
H
Handlebar Adjustment . . . . . . . . . 158
Hauling Cargo. . . . . . . . . . . . 110-111
Helmet . . . . . . . . . . . . . . . . . . . . . . 92
Horn . . . . . . . . . . . . . . . . . . . . . . . . 69
Horn Button . . . . . . . . . . . . . . . . . . 19
203
Index
I-J
Indicator Light . . . . . . . . . . . . . . 164
Indicator Lights. . . . . . . . . . . . . . . 77
K
Key Switch . . . . . . . . . . . . . . . . . . 67
Kick-Start Lever . . . . . . . . . . . 20, 82
K-Turn . . . . . . . . . . . . . . . . . . . . 102
L
Lamp Replacement
Daytime Running Lights . . 165
Indicator Light . . . . . . . . . . 164
Tail Light . . . . . . . . . . . . . . 163
Lights, Indicator . . . . . . . . . . . . . . 77
Lights, Daytime Running . . . . . . 165
Lubrication Guide . . . . . . . . . 122-123
M
Main Key Switch . . . . . . . . . . . . . 67
Maintenance Chart . . . . . . . . 114-121
Making Turns . . . . . . . . . . . . . . . . 95
Modifications . . . . . . . . . . . . . . . . 15
N
No Passenger Warning. . . . . . . . . . 39
O
Oil. . . . . . . . . . . . . . . . . . . . . . . . . 124
Oil Change, Engine . . . . . . . 126-128
Oil Change, Transmission . . . . . . 131
Oil Check, Engine . . . . . . . . . . . . 125
Oil Check, Transmission . . . . . . . 130
Oil, Engine . . . . . . . . . . . . . . . . . . 124
Operation Warning. . . . . . . . . . . . . 35
P
Parking on a Hill or Incline . . . . . 105
Passenger Warning. . . . . . . . . . . . . 39
Periodic Maintenance Chart. 114-121
Polaris Products . . . . . . . . . . . . . . 182
Polishing. . . . . . . . . . . . . . . . . . . . 172
Pre-Ride Inspection . . . . . . . . . 85-87
Product Safety Commission. . . . . . 14
R
Rack Warning . . . . . . . . . . . . . . . . 40
Riding Gear . . . . . . . . . . . . . . . 92-93
S
Safety Training . . . . . . . . . . . . . . . . 7
Seat Latch . . . . . . . . . . . . . . . . . . . 21
Severe Use. . . . . . . . . . . . . . . . . . 115
Shift Lever. . . . . . . . . . . . . . . . 20, 72
Shock Spring Adjustment . . . . . . 152
Signal words . . . . . . . . . . . . . . . . . . 8
Spark Arrestor . . . . . . . . . . . . 138-139
Spark Plug Change . . . . . . . . . . . 133
Spark Plugs . . . . . . . . . . . . . . 132-133
Specifications
Outlaw 90 . . . . . . . . . . . 178-179
Sportsman 90 . . . . . . . . 180-181
Speed Control System . . . . . . 142-143
Start Button . . . . . . . . . . . . . . . . . . 69
Starting the Engine . . . . . . . . . . 88-90
Steering Inspection . . . . . . . . . . . 152
Stop Switch . . . . . . . . . . . . . . . . . . 68
Stopping the ATV . . . . . . . . . . . . . 24
Stopping the Engine . . . . . . . . . . . 91
Storage. . . . . . . . . . . . . . . . . . 173-176
204
Index
S
Switches
Engine Start Button . . . . . . . . 69
Engine Stop Switch . . . . . 19, 68
Horn Button. . . . . . . . . . . . . . 19
Ignition Switch . . . . . . . . . . . 23
Main Key Switch. . . . . . . . . . 67
Tether Switch . . . . . . . . . . . . 23
T
Tail Light . . . . . . . . . . . . . . . . . . . 163
Tether Strap . . . . . . . . . . . . . . . . . . 23
Throttle . . . . . . . . . . . . . . . . . . . . . 70
Throttle Cable Adjustment . . . . . 144
Throttle Control . . . . . . . . . . . . . . . 19
Throttle Lever . . . . . . . . . . . . . . . . 71
Throttle Stop Speed Control System . .
143
Tire Pressure Warning
Outlaw 90 . . . . . . . . . . . . . . . 37
Sportsman 90 . . . . . . . . . . . . 38
Tire Tread Depth . . . . . . . . . . . . . 160
Tires. . . . . . . . . . . . . . . . . . . . . . . 159
Toe Alignment. . . . . . . . . . . 150-151
Transmission Oil . . . . . . . . . 130-131
Transporting the ATV . . . . . . . . . 177
Turning Around on a Hill . . 102-103
V
Vehicle Identification Numbers . . . 66
Vehicle Immersion . . . . . . . . 134-135
W
Warranty . . . . . . . . . . . . . . . . 196-197
Warranty, Emissions. . . . . . . 196-197
Washing the ATV . . . . . . . . . . . . . 170
Wheel Hub Tightening . . . . . . . . . 162
Wheel Installation. . . . . . . . . . . . . 161
Wheel Nuts . . . . . . . . . . . . . . . . . . 162
Wheel Removal . . . . . . . . . . . . . . 160
