The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
WARNING
2
Copyright 2004 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 contained
within, whether whole or in part, is expressly prohibited. Printed in Taiwan.
2005 Predator 50/Predator 90/Sportsman 90 Owner’s Manual P/N 9919505
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
learning 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 l earn to operate
the ATV with safety as a top priority. Help them also learn to show respect for our
environment and for t he rights of others while operating the ATV.
Children differ in skills, physical abilities and judgement. Some children m ay 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 i nspected at various intervals. For
safe and enjoyable operation of t he vehicle, be sure to follow all of the instructions and
recommendations 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 P olaris 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 t he
warnings and instructions you read. Your safety and the safety of others is the m ost
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
Welcome 3.................
Safety 7....................
Youth Section 17............
Know Your ATV 18........
Pre-Ride Check 25........
Riding Rules 28...........
Adult Section 33............
Safety Decals 34..........
Driver Warnings 47........
Vehicle ID Numbers 70....
Features and Controls 71..
Break-in Period 88........
Pre-Ride Inspections 90...
Starting the Engine 91.....
Stopping the Engine 93....
Driving Safely 94..........
Hauling Cargo 112........
Emission Control 115......
Maintenance 116.........
Specifications 160.........
Polaris Products 166......
Troubleshooting 168.......
Warranty 174.............
Index 180...................
6
7
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 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.
Safety Training
When you purchased this ATV, your Polari s dealer offered a hands-on safety training course
that covers all aspects of ATV safety. In addition, you were provided with printed material
and a video that i nstructs operators on safe operating procedures. You should review this
information with your child on a regular basis. If you purchased a used Polaris ATV from a
party other than a Polaris dealer, you can request this free safety training from any
authorized Polaris dealer.
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 personal 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 hazard that may result in
minor personal 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 precautions.
Read and understand the owner’s manual and all warnings before operating a Polaris
ATV.
10
Safety
S Read this manual and all labels carefully
and follow the operating procedures de-
scribed.
S Never operate an ATV without proper
instruction. Take a training course.
Riders should receive training from a
certified instructor. Contact an autho-
rized Polaris ATV dealer or call Polaris
at 1-800-342-3764 to find out about the
training courses neares t you.
S Always follow the age guidelines for
your machine: 90cc models are de-
signed for children not less than 12
years of age and 50cc models are de-
signed 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.
S Do not allow other children to ride this
ATV unless they have read the manual,
seen the instructional video and taken
and passed a Polaris approved riding
skill test.
S Always avoid operating an ATV on any
paved surfaces, including sidewalks,
driveways, parking lots and streets.
S Never operate an ATV on any public
street , road or highway, including dirt or
gravel roads.
S 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
S Never operate an ATV without wearing
an approved helmet that fits properly.
You should also wear eye protection
(goggles or face shield), gloves, boots,
long-sleeved shirt or j acket, and long
pants.
S Never consume alcohol or drugs before
or while operating this ATV.
S Never operate at excessive speeds. Al-
ways travel at a speed which is proper
for the terrain, visibility and operating
conditions, and your experience.
S Never attempt wheelies, jumps or other
stunts.
S 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.
S Always keep both hands on the handle-
bars and both feet on the footrests of the
ATV during operation.
S Always go slowly and be extra careful
when operating on unfamiliar terrain.
Always be alert to changing terrain con-
ditions when operating t he ATV.
S Never operate on excessively rough,
slippery or loose terrain.
12
Safety
S Always follow proper procedures for
turning as described in this manual.
Practice turning at low speeds before at-
tempting to turn at faster speeds. Do
not turn at excessive speed.
S Always have the ATV checked by an
authorized Polaris dealer if it has been
involved in an accident.
S Never operate the ATV on hills too
steep for the ATV or for your abilities.
Practice on smaller hills before attempt-
ing larger hills.
S Always follow proper procedures for
climbing hills as descri bed in this manu-
al. Check the terrain carefully before
you start up any hill. Never climb hills
with excessively slippery or loose sur-
faces. Shift your weight forward. Nev-
er open the throttle suddenly or make
sudden gear changes. Never go over the
top of any hill at high speed.
S 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 back-
ward. 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
S Always follow proper procedures for
crossing the side of a hill as described in
this manual. Avoid hills with excessive-
ly 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
turning technique described in this
manual on level ground. Avoid crossing
the side of a steep hill if possible.
S 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. Dismount on the uphill
side or to either side if pointed straight
uphill. Turn the ATV around and re-
mount, following the procedure de-
scribed in this manual.
S Always be careful of skidding or slid-
ing. On slippery surfaces, such as ice,
go slowly and be very cautious in order
to reduce the chance of skidding or slid-
ing out of control.
14
Safety
S 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.
S Avoid operating t he ATV through deep
or fast flowing water. If you cannot
avoid water which exceeds the recom-
mended maximum depth (pg. 108), 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.
S Wet brakes may have reduced stopping
ability. Test your brakes after leaving
water. If necessary apply t hem lightly
several times to let friction dry out the
pads.
S Always use the size and type tires speci-
fied in this manual. Always maintain
proper tire pressure as described in this
manual.
S Never modify an ATV through improper
installation or use of accessories.
S Never exceed the stated load capacity
for an ATV.
S Always remove the ignition key when
the vehicle is not in use to prevent unau-
thorized 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 t he vehicle
create a substantial 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: Polari s Youth ATVs are equipped with an electronic 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 135.
These units are not designed for adult use. Serious damage to the vehicle may occur i f the
maximum rider weight capacity is exceeded. See the specifications section beginning on
page 160 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
controls on your new ATV.
1. Engine Stop Switch - When the engine is running, push this button down to shut the
engine off quickly. The button must be up before you can start the engine again.
2. Horn Button (90 cc models) - 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.
1
3
2
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 86.
5. Shift Lever (90cc models) - The shift lever
is on the right side of your ATV. Read
about how to use the shift lever on page 76.
4
5
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 - To remove the seat, pull up
on the seat latch on the lefthand side of 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
7
22
Know Your ATV
8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop
the ATV. The lefthand lever (8A) controls the rear brake. The righthand lever (8B)
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.
8A
8B
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 m ust always be attached snugly t o your
right wrist and to your ATV every time you drive. If you fall off your ATV, the t ether
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.
9
10
9
10
24
Know Your ATV
Let’s review the three ways to stop your ATV:
1. Push the stop switch down.
2. Pull off the tether strap.
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.
Make sure the throttle doesn’t stick. Check this by pushing the throttle lever t oward t he
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
Make sure the brakes don’t stick. Check the brake levers by squeezing them toward the
handlebar and then l etting 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.
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 t hey must read the instructions and warnings on page 83 of this manual.
Always have an adult put gas in your ATV. Never try to do it yourself.
27
Pre-Ride Check
If you used the storage area under the seat, make sure the seat is locked in place.
Have an adult check the engine oil level when the engine is cold. The engine is very hot
after it has been running and i t can burn your skin if you touch it. C hildren 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.
This last check is done with the engine running. You must check to make sure that all
three ways to stop your AT V are working the way they should. Do you remember what
they are? If you can’t remember the three ways to stop your ATV, go back to page 24
and review. Then have an adult help you start your ATV and practice stopping the en-
gine 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 s ome 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.
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
" Always wear the right kind of clothing and safety gear when riding your ATV.
1. Helmet: Your helmet i s very important for safe riding.
A helmet can prevent a severe head injury.
2. Eye Protection: Always wear shatterproof goggles or a
helmet face shield, and always keep them clean so you can
see where you’re driving.
3. Gloves: Wear gloves to protect your hands from sun and
wind. Gloves will also protect your hands from scrapes and
scratches.
4. Boots: Wear sturdy boots to keep your feet dry. Boots
will also protect your feet and ankles from scrapes and
scratches.
5. 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.
1
2
3
4
5
30
Riding Rules
" Always attach the tether strap to your right wrist and
to the ATV before riding.
" 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.
" Your ATV is made for one person. Never carry
a passenger. A passenger will make the ATV
harder to drive. You you may lose control and
hurt yourself and your passenger.
" Always drive your ATV while sitting down.
Keep both hands on the handlebars and keep
both feet on the footrests.
" Always be alert and pay attention t o 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.
" Never follow another ATV too closely. You need lots of time and space to stop your
ATV.
31
Riding Rules
" Never ride alone. An adult should always be watching you in case you need help. Al-
ways drive within the sight of an adult.
" Never ride on public trails.
" 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.
" Don’t ride at night. Your ATV doesn’t have lights that are safe for driving in the dark.
" Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away
from them.
" Never ride on frozen water. You could get hurt or you could even die. All ice can be
dangerous!
" 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.
" Always be a polite driver. (No driving through the flower garden or over the little trees
you planted.)
" 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 and safety decals have been placed on the ATV for the protection of the operator.
Read and follow the instructions on each decal carefully. If any safety decal becomes
illegible or comes off, contact your Polaris deal er for a free replacement. The part number
is printed on the decal.
L
7172678
35
Safety Decals
Improper ATV u se 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.
AL WAYS 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
W ARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR
A REPLACEMENT.
36
Safety Decals
Predator 50 Age Warning Decal
S Kids under age 6 should NEVER operate this A TV.
Kids under 6 have an increased chance of losing
control, which could result in severe injury or death.
S Adult supervision is required.
S Make sure operators follow Owner’s Manual and
labels.
S Make sure operators watch the safety video and
pass the ATV Training Course.
S Never operate this A TV on HILLS steeper than 15
degrees 15°. To prevent flipover on hilly terrain,
use throttle and brakes gradually.
L
7172683
37
Safety Decals
Predator 50 Age Warning Decal
S Kids under age 6 should NEVER operate this ATV. Kids under 6 have an increased
chance of losing control, which could result in severe injury or death.
S Adult supervision is required.
S Make sure operators follow Owner’ s Manual and labels.
S Make sure operators watch the safety video and pass the ATV T raining Course.
S Never operate this ATV on HILLS steeper than 15 degrees
15°. To prevent flipover on
hilly terrain, use throttle and brakes gradually.
38
Safety Decals
Predator 90/Sportsman 90 Age W arning Decal
S Kids under age 12 should NEVER operate this A TV. Kids
under 12 have an increased chance of losing control,
which could result in severe injury or death.
S Adult supervision is required.
S Make sure operators follow Owner’s Manual and labels.
S Make sure operators watch the safety video and pass
the ATV Training Course.
S Never operate this A TV on HILLS steeper than 15 de-
grees 15°. To prevent flipover on hilly terrain, use
throttle and brakes gradually .
S REVERSE operation can be dangerous even at low
speeds. Steering becomes difficult. To prevent flipover,
avoid sudden braking or sharp turns.
L
7173040
39
Safety Decals
Predator 90/Sportsman 90 Age W arning Decal
S Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased
chance of losing control, which could result in severe injury or death.
S Adult supervision is required.
S Make sure operators follow Owner’ s Manual and labels.
S Make sure operators watch the safety video and pass the ATV T raining Course.
S Never operate this ATV on HILLS steeper than 15 degrees
15°. To prevent flipover on
hilly terrain, use throttle and brakes gradually.
S REVERSE operation can be dangerous even at low speeds. Steering becomes difficult.
To prevent flipover, avoid sudden braking or sharp turns.
40
Safety Decals
2
1
2
1
1
7172566
WARNING
41
Safety Decals
IMPROPER TIRE PRESSURE OR OVERLOADING can cause
loss of c ontrol resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT 3 (20.7) REAR 3 (20.7)
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight INCLUDING
MACHINE, DRIVER AND CARGO IS 481 LBS./218 KG)
Reduce speed and allow greater distance for braking when
carrying cargo. Overloading or carrying 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 distribution 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.
(Sportsman 90)
2
WARNING
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control,
resulting in SEVERE INJURY OR DEATH.
TIRE PRE SSURE (PSI): FRONT 3 (20.7) REAR 3 (20.7)
MAXIMUM WEIGHT CAPACITY
(Gross Vehicle Weight) INCLUDING MACHINE,
DRIVER AND CARGO IS 437 LBS. (198 KG)
2
(Predator 90)
WARNING
7172682
2
(Predator 50)
WARNING
IMPROPER TIRE PRESSURE OR
OVERLOADING can cause loss of control,
resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE (PSI): FRONT 2 REAR 2
MAXIMUM WEIGHT CAPACITY
(Gross Vehicle Weight) INCLUDING MACHINE,
DRIVER AND CARGO IS 311 LBS.
7172684
7172681
42
Safety Decals
3
4
43
Safety Decals
ATTENTION
S Operation of this vehicle without the filter
element will severely damage the engine.
S Clean air filter often, more frequent clean-
ing required in dusty conditions.
3
S Specific carburetor jetting and
adjustments are required depending
on temperature and altitude. See your
Owner’s Manual.
Factory Setting:
40° to 80° F. at 0-3000 feet.
(5° to 27° C. at 0-900 meters)
(on air filter box)
(on rear of seat)
4
44
Safety Decals
5
6
6
5
45
Safety Decals
5
Moving part s haz ard under belt -clut ch guar d. To pr event serious injury, do
not operat e vehic le wit h guar d rem oved.
Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM which can result in serious injury or death.
MANUFACTURED
IN TAIWAN
DATE:
VIN:
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS
NOT INTENDED FOR USE ON PUBLIC ROADS.
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN
QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR
LES CHEMINS PUBLICS.
DO NOT TOW FROM RACK OR BUMPER. Vehicle
damage or tipover may result c ausing s evere injury
or death. Tow only from tow hooks or hitch.
Maximum Rack Loads: Front 10 lbs.; Rear 20 lbs.
6
(Sportsman 90)
WARNING
WARNING
7172679
7172680
46
47
Driver Warnings
Be sure to read all o f the follo win g warnings
about driving hazards and how to avoid them.
These warnings are provided for your child’s safety,
so be sure to explain to your young driver that
the following hazards MUST be avoided at all times.
48
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 certified training course offered by Polaris Industries
Inc. They should then regularly practice the skills
learned in the course and the operating techniques
described in the Owner’ s Manual.
For more information about the training course, contact
an authorized ATV dealer or call Polaris at
1-800-342-3764.
49
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 guidelines printed on your machine.
50
Driver Warnings
WARNING
POTENTIAL HAZARD
Carrying a passenger on this ATV.
WHAT CAN
HAPPEN
Greatly reduces your ability to balance and control
this ATV.
Could cause an accident, resulting in harm to you
and/or your passenger.
HOW TO AVOID THE
HAZARD
Never carry a passenger. The long seat is to
allow the operator to shift position as needed
during operation. It is not for passengers.
51
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.
52
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 public
street, road or highway, even a dirt or
gravel one.
In many states it is illegal to operate
ATVs on public streets, roads and
highways.
53
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV without wearing an approved
helmet, eye protection and protective clothing.
WHAT CAN
HAPPEN
Operating without an approved helmet increases
your chances of a severe head injury or death in
the event of an accident.
Operating without eye protection can result in an
accident and increases your chances of a severe
injury in the event of an accident.
HOW TO AVOID THE
HAZARD
Always wear an approved helmet which fits
properly. You should also wear: eye protection
(goggles or face shield); gloves; boots;
long-sleeved shirt or jacket; and long pants.
54
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating this ATV after consuming
alcohol or drugs.
WHAT CAN
HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE
HAZARD
Never consume alcohol or drugs before or while
driving this ATV.
55
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 condition.
Always follow the inspection and
maintenance procedures and
schedules described in the Owner’s
Manual.
56
Driver Warnings
WARNING
POTENTIAL HAZARD
Attempting wheelies, 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 wheelies, jumps, or other
stunts. Avoid exhibition driving (don’t show
off).
57
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 reduce your
ability to control the ATV or could cause you to
lose your balance and fall off the ATV. If you
remove a foot from the footrest, your foot or leg
may come into contact with the rear wheels,
which could injure you or cause an accident.
HOW TO AVOID THE
HAZARD
Always keep both hands on the handlebars and
both feet on the footrests of your ATV during
operation.
58
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.
Could result in the ATV overturning or
going out of control.
HOW TO AVOID THE
HAZARD
Go slowly and be extra careful when
operating on unfamiliar terrain.
Always be alert to changing terrain
conditions when operating the ATV.
59
Driver Warnings
WARNING
POTENTIAL HAZARD
Failure to use extra caution when operating
on excessively 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 necessary to control
the ATV on such terrain.
Always use extra caution on rough, slippery or loose terrain.
60
Driver Warnings
WARNING
POTENTIAL HAZARD
T urning 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.
61
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 100.
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.
62
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 106.
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.
63
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 104. 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.
64
Driver Warnings
WARNING
POTENTIAL HAZARD
Stalling, rolling backwards or improperly
dismounting while climbing a hill.
WHAT CAN
HAPPEN
The ATV could overturn.
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 104.
65
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.
66
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
NeverrideyourATVonafrozen
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.
67
Driver Warnings
WARNING
POTENTIAL HAZARD
Operating the ATV through deep or fast-flowing water.
WHAT CAN
HAPPEN
T ires may float, causing loss of traction and loss of control, which could lead to an
accident or overturn.
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 108), 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 necessary, apply them several times to let friction dry out the pads.
68
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 properly distributed and securely
attached.
WARNING
POTENTIAL HAZARD
Operating the ATV with improper
modifications.
WHAT CAN
HAPPEN
Improper installation of accessories
or modification of the ATV may cause
changes in handling 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.
69
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.
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.
WARNING
After a rollover or an accident, have
a qualified service dealer check the
complete machine including, but not
limited to, brakes, throttle and
steering for possible damage.
70
Vehicle Identification Numbers
Record your ATV’s identification numbers and key number
in the spaces provided. Remove the spare key and store it
in a safe place. Your key can be duplicated only by mating
a P olaris key blank with one of your existing keys, so if
both keys are lost, the ignition switch must be replaced.
The Predator 50 VIN is located on the righthand lower
frame tube. The Predator 90 and Sportsman 90 VIN is
located on the righthand front upper shock mount.
Vehicle Model Number:
Frame VIN:
Engine Serial Number (1):
Key Number:
1
71
Features and Controls
Main Switch (A)
The main switch is located on the pod. This switch is operated with a key and must be
turned clockwise to the ON position before starting the engine.
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.
A
A
72
Features and Controls
Engine Stop Switch (B)
The stop switch (B) is located on the top of the left handlebar. The engine will not start or
run when the stop switch is down, in the OFF position. Its purpose is to provide the
operator with a quick means of engine shutdown in case of stuck throttle or other
emergency. NOTE: Both the main switch and the emergency engine stop switch shut off
all electrical power to the entire vehicle. To stop the engine quickly, push t he stop switch
down.
Choke Lever (C)
The choke lever (C) is located on the bottom of the left handlebar. The choke is used when
starting a cold engine. Push t he 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.
Horn Button (D)
The horn button is l ocated on the lefthand control (Sportsman 90 and Predator 90).
B
C
E
D
73
Features and Controls
Engine Start Button (E)
The start button is located slightly above the choke lever. To start t he engine, make sure
the tether strap is securely plugged i nto t he machine and attached to the rider’s right wrist.
If you have a 90cc model, make sure the shift lever is in neutral. The neutral light will
come on when the lever is in neutral. See page 81.
1. Turn the key to the ON position.
2. Set the parking brake.
3. Push the start button up t o
the ON position.
4. Press the start button.
74
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.
75
Features and Controls
Throttle L ever
Engine speed and vehicle movement are
controlled by pressing the throttle lever (A).
The throttle lever is spring loaded. 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.
A
76
Features and Controls
Shift Lever (90cc models)
To change gears, stop the ATV. With the
engine idling, move the lever (1) to the
desired gear. Do not try to shift gears
with engine speed above idle or while the
ATV is moving.
Maintaining shift linkage adjustment is
important to assure proper transmission
function. See your dealer if you
experience any shifting problems.
Shift Pattern
F: Forward Gear
N: Neutral
R: Reverse
F
N
R
1
77
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 whenever the vehicle is left unattended.
78
Features and Controls
Brakes
To activate the rear brake, squeeze the lefthand lever (A) toward the handlebar. The front
brakes are activated by squeezing the lever (B) on the righthand handlebar.
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.
A
B
79
Features and Controls
Brakes
Setting the Parking Brake
1. Squeeze the lefthand brake lever (A).
2. Push the park brake lock (B) down.
This will prevent the lever from
returning to t he released position.
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.
A
B
B
80
Features and Controls
Brakes
Parking Brake
NOTE: The Predator 50 has a PVT system that’s always in forward. Always lock the park
brake before starting the engine. Since the transmission is always in forward gear,
activating the throttle to warm the engine will make the machine move forward if t he park
brake is not locked.
On 90cc models, always shift the transmission to neutral and lock the park brake before
starting the engine.
After the engine has warmed enough for operation, shift to the desired gear (90cc models).
Release the park brake and gently apply the throttle.
Always lock the parking brake whenever the vehicle is left unattended.
81
Features and Controls
Lights
WARNING
Polaris Youth ATVs are not equipped with lights. The ATVs are designed for off-road
use only and must not be ridden on streets or highways. Use caution and drive at
reduced speeds in conditions of reduced visibility. Do not operate this ATV after dark.
Indicator Lights
Indicat or lights on the ATV let you
know when your ATV is in neutral or
reverse (90cc models). The low oil
light comes on if the engine oil level
gets too l ow. If this happens, turn
the engine off and have an adult
check your ATV.
N: Neutral (Green)
R: Reverse (Amber)
O: Low Oil (Red)
O
N
R
R
O
N
82
Features and Controls
Oil System
CAUTION
Mixing brands or using a non-recommended oil may cause serious engine damage.
We recommend the use of Polaris VES II Synthetic 2-cycle oil or Polaris Premium
Gold Synthetic 2-cycle oil. Never substitute or mix oil brands.
To avoid serious engine damage, always top off the oil level when refueling.
The oil tank (A) i s located under
the seat and has a capacity of 1.1
quarts (1 liter). Always top off the
oil level when refueling.
NOTE: See page 21 for seat
removal instructions.
A
83
Features and Controls
Fuel System
WARNING
Gasoline is highly flammable and explosive under certain conditions.
S Always exercise extreme caution whenever handling gasoline.
S Always refuel with the engine stopped, and outdoors or in a well ventilated area.
S Do not smoke or allow open flames or sparks in or near the area where refueling is
performed or where gasoline is stored.
S Do not overfill the tank. Do not fill the tank neck.
S If gasoline spills on your skin or clothing, immediately wash it off with soap and wa-
ter and change clothing.
S 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.
S Turn the fuel valve off whenever the ATV is stored or parked.
84
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.
Gas Cap
The fuel tank filler cap (A) is located directly below
the handlebars. The tank has a capacity of 1.3
gallons (5 liters). Use unleaded gasoline with a
minimum pump octane of 87.
A
85
Features and Controls
Fuel System
Fuel V alve
The fuel valve is located on the lefthand
side of the ATV. It has three positions:
OFF: For vehicle storage and when
transporting.
ON: For normal operation.
RES: For reserve supply if main supply
is exhausted.
NOTE: There’s about a 7-10 mile (11-16 km)
range on reserve gas. Always refill the gas
tank as soon as possible after using the main
supply. Always return the valve to the ON position after refueling.
Fuel Filter
The P olaris ATV is equipped with an in-line fuel filter. This filter should be replaced by
your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel
filter.
RES
ON
OFF
Sportsman Predator
86
Features and Controls
Kick-Start Lever
If the battery becomes too weak to start the engine, the
kick-start lever will allow you to start the engine until the
battery is serviced. Be sure the ATV is on a level surface with
the parking brake locked. Make sure the transmission is in
neutral (90cc models).
1. Fold out the kick-start lever (A) on the lefthand side of the
ATV.
2. Make sure the stop switch is in the RUN position and turn
the key to ON.
3. Place your foot on the kick-start, and then thrust your heel
downward to crank the engine.
4. After the engine has started, fold the kick-start lever back
into place. NOTE: A 10/12mm wrench i s provided in the
tool kit for removing or installing the lever. If not installed, make sure the rubber cap
is installed on the kick-start shaft to protect the rider. On 50cc models, store the
kick-start lever under the seat (B) when it’s not installed on t he ATV.
A
B
87
Features and Controls
Footwell Riser
The removeable footwell risers on the Predator
50 improve riding ergonomics and provide
comfort for shorter operators. An operator will
also have better control of the ATV when both
feet can remain firmly planted on either the
footwells or the risers. If the operator’s legs are
long enough to comfortably reach the footwells
without the risers, the risers can be removed.
1. Remove the rubber caps (A) covering
the screw access holes.
2. Remove the six screws (B) and nuts
securing the footwell riser (C) to the
footwell and remove the riser.
3. Reverse t he procedure to reinstall the
footwell riser for shorter operators.
A
B
C
88
Break-in Period
The break in period for your new Polaris ATV is the length of time it takes to use the first
tank of gas. No single action on your part is as important as following the procedures for a
proper break-in. Careful treatment of a new engine will result in more efficient
performance and longer life for the engine. Perform the following procedures carefully.
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.
Use of any lubricants other than those recommended by Polaris may cause serious
engine damage. We recommend the use of Polaris lubricants for your vehicle.
1. Mix 6.4 ounces of recommended oil to two gallons of gasoline in an appropriate gas
container and fill the fuel tank as outlined on pages 83-84. NOTE: After the break-in
period the oil injection system provides the necessary engine lubrication without the
need for pre-mixed fuel.
89
Break-in Period
2. Fill the oil tank with Polaris-recommended oil. NOTE: Always be sure to top off the
oil level whenever refueling.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with
vehicle operation and handling.
4. Vary the 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. See page 90.
6. After the first tank of pre-mixed fuel has been used, check to see if the oil level in the
oil tank has dropped, indicating t hat the oil pump is functioning properly. If the level
has not dropped, see your dealer for oil pump bleeding and then repeat the pre-mix
procedure.
90
Daily 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.
Use the following checklist t o make sure the ATV is i n proper working condition before
each use.
Item/Inspection Procedure
1. Tires - Check condition and pressures.
2. Fuel and oil tanks - Fill both tanks.
3. All brakes - Check operation/adjustment.
4. Throttle - Check for free operation and
proper closing.
5. Brakelight - Check for proper operation.
6. Engine stop switc h - Check for proper
function.
7. Wheels - Check for tightness of wheel
nuts and axle nuts; check that axle nuts
are secured by cotter pins.
8. Drive chain - Condition and slack; refer to
drive chain adjustment.
9. Air cleaner element - Check for dirt;
clean or replace.
10. Steering - Check for free operation noting
any unusual looseness in any area.
11. Loose parts - Visually inspect vehicle for
any damaged components or loose
nuts/bolts or fastene rs.
12. Riding gear - Wear a helmet, goggles and
protective clothing.
91
Starting the Engine
WARNING
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting 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.
1. Shift the transmission to neutral (90cc models).
2. Set the parking brake and turn the fuel tank valve to ON.
3. 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.
92
Starting the Engine
4. 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.
5. Turn the engine stop switch to R UN, then turn the ignition key to ON. NOTE: Do not
press the throttle while starting the engine.
6. Squeeze the rear brake lever and press the starter button.
NOTE: The rear brake lever must be engaged or the engine won’t start.
7. 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.
8. 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.
9. When the engine idles smoothly, push the choke lever all the way to the right.
93
Stopping the Engine
1. Release the throttle completely and brake to a complete stop.
2. Put the shift lever into neutral (90cc models).
3. Lock the parking brake.
WARNING
A rolling vehicle can cause property damage and serious injury. Always apply the
parking brake after stopping the engine.
94
Driving Safely
Safe 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.
1. Helmet
Your helmet is the most important piece of protective gear
for safe riding. A helmet can prevent a severe head injury.
Select an approved helmet that meets or exceeds your
state’s safety standards and bears either the Department of
Transportation (DOT) label, the American National
Standards Institute label (ANSI z90.1), or the Snell
Memorial Foundation label.
1
2
3
4
5
95
Driving Safely
2. Eye Protection
Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face
shield offer the best protection for your eyes. They should be kept clean and be of
shatterproof design (bearing the markings z2.1 or VESC 8).
3. Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
4. Boots
The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.
5. Clothing
Always wear long sleeves and long pants t o protect arms and legs. Riding pants with
kneepads and a jersey with shoulder pads provide the best protection.
96
Driving Safely
Driving Procedure
1. Sit upright with both feet on the footrests and both
hands on the handlebars.
2. Place the transmission in neutral (90cc models).
3. Start the engine and allow it to warm up.
4. Check your surroundings and determine
your path of travel .
5. Squeeze the brake levers.
6. Shift the transmission to the desired gear
(90cc models).
7. Release t he parking brake and slowly
release the brake levers.
8. Slowly depres s the throttle with your right thumb and begin driving.
9. Drive slowly and practice turning and using the throttle and brakes on level
surfaces.
97
Driving Safely
Making Tu rns
Your ATV is equipped with a solid rear axle, which drives both
rear wheels equally at all times. This means that t he wheel on
the outside of the t urn 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
T urning 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.
98
Driving Safely
Driving on Slippe ry 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.
99
Driving Safely
Whenever riding on slippery surfaces such as wet trails
or loose gravel, or during freezing weather, follow
these precautions:
1. Slow down when entering s lippery 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.
100
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.
101
Driving Safely
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 t he
vehicle.
15_ Maximum
102
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.
103
Driving Safely
Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If
you do enter i nto a situation where sidehilling is necessary, follow these precautions:
1. Slow down.
2. Lean into the hill, transferring your
upper body weight uphill while
keeping your feet on the footrests.
3. 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
immediately!
104
Driving Safely
Turning Around on a Hill
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.
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 (90cc models).
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.
105
Driving Safely
5. Staying uphill of the ATV, turn the handlebars full left.
6. While holding the brake, release the parking brake lock and slowly release the brake,
allowing the ATV to roll around to your right until it’s pointing across the hill or
slightly downward.
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 (90cc models).
11. Release the parking brake and
drive slowly, controlling speed
with the rear brake, until the ATV
is on more level ground.
8’
Uphill
106
Driving Safely
Driving Downhill
Whenever descending a hill, follow t hese
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.
107
Driving Safely
Parking o n a Hill or Incline
Avoid parking on a hill or incline if
possible. If it’s unavoidable, follow these
precautions:
1. Turn the engine off.
2. Set the parking brake.
3. Always block the rear wheels on the
downhill side as shown i n the
illustration.
4. Shut off the fuel supply.
108
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 (A). 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 until
braking action is normal. If you do not perform this procedure, your brakes may be
ineffective.
A
109
Driving Safely
Avoid operating your ATV through deep or fast flowing water. If the ATV is operated i n
deeper water than recommended, it’s critical to have it serviced as outlined in the
maintenance chart beginning on page 122. The following areas need special attention:
engine oil, gearcase oil, front and rear gearcases 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.
110
Driving Safely
Driving Over Obstacles
Be alert! Look ahead and learn to read the
terrain you’re traveling on. Be constantly
alert for hazards such as logs, rocks and
low hanging 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.
111
Driving Safely
Driving in Reverse (90cc models)
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 operation procedures outlined in this manual. Always back
slowly.
112
Hauling Cargo
The Sportsman 90 was designed to carry a certain amount of load. Never exceed the
weight capacities listed in the specifications section of the owner’s manual. Never carry
cargo on a Scrambler.
Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack)
and mounted as low as possible. When operating over rough or hilly terrain, reduce speed
and cargo weight to maintain stable driving conditions.
WARNING
Hauling cargo improperly can alter vehicle handling and may cause loss of control or
brake instability and result in serious injury or death. Always heed the warnings on
the following pages.
113
Hauling Cargo
S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING
WHEN CARRYING CARGO.
S CARGO WEIGHT DISTRIBUT ION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and cargo
to maintain stable driving conditions. Carrying loads on one rack only increases
the possibility of vehicle tip over.
S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations which may require backing downhill.
(continued on following page)
2/3 of Load
on
Rear Rack
1/3 of Load
on
Front Rack
114
Hauling Cargo
S ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unse-
cured loads can create unstable operating conditions, which could result in loss of
control of the vehicle.
S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE.
Carrying loads high on the racks raises the center of gravity of the vehicle and
creates a less stable operating condition. When cargo loads are carried high on
the r acks, the weight of the loads must be reduced to maintain stable operating
conditions.
S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS.
When handling off-centered loads which cannot be centered, securely fasten load
and operate with extra caution.
S EXTREME CAUTION MUST BE USED when operating with loads extending
over the rack sides. Stability and maneuverability may be adversely affected,
causing the machine to overturn.
S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
115
Emission Control Systems
Noise Emission Con t rol System
Do not modify the engine, intake or exhaust components, as doing so may affect
compliance with state and local noise level requirements.
Spark Arrestor
Your Polaris ATV is not equipped with a spark arrestor approved by the USDA Forest
Service. Operating this ATV on U.S. public lands without a spark arrestor is in violation of
federal law.
116
Maintenance
PVT System
WARNING
The PVT system rotates at high speeds, creating large amounts of force on clutch
components. Extensive engineering and testing has been conducted to insure the
safety of this product. However, as the owner you have the following responsibilities
to make sure this system remains safe:
Do not modify any component of the PVT system. Doing so may reduce its strength
so that a failure may occur at high speeds. This system has been precision balanced.
Any modification will cause the system to be out of balance, creating vibration and
additional loads on components.
S Routine maintenance is the responsibility of the owner. Always follow recommended
maintenance procedures. See your dealer!
S This PVT system is intended for use on Polaris products only.
S The PVT housing must be securely in place during operation.
Failure to comply with this warning can result in severe injury or death.
117
Maintenance
PVT System
If the ATV is operated in dusty areas, clean the PVT filter more often than recommended
for normal conditions. To clean the PVT filter:
1. Remove the screws and the crankcase cover.
2. Remove the screws and the filter cover.
3. Soak the filter in a mild detergent and rinse with clean water.
4. Allow the filter to air dry, then reinstall.
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.
118
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.
119
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.
120
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 rechar ging is necessary, use a .5
amp battery charger.
Battery Storage
When the vehicle is placed in storage for three months or more, the battery should be
removed, stored out of the sun in a cool, dry place and t ested monthly. Before reusing, take
the battery to your dealer for testing and recharging on a .5 amp battery charger.
121
Maintenance
Periodic Maintenance Schedule
To help you perform routine maintenance, a tool kit is provided in the storage compartment
under the seat. Items included in the kit are:
S Sparkplugwrench
S Screwdriver
S Tire pressure gauge
Maintenance intervals are based upon average riding conditions and an average vehicle
speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as
operation in wet or dusty areas, should be inspected and serviced more frequently.
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.
122
Maintenance
Periodic Maintenance Schedule
Hours of operation are based on a 10 mph average. If service is due at 20 hours, the
equivalent odometer reading would be 200 miles. Perform all services at whichever
reading is reached first.
WARNING
Improperly performing the procedures marked with a J could result in component
failure and lead to serious injury or death. Have an authorized Polaris dealer perform
these services.
Maintenance Chart Key
" Perform these operations more often under severe use, such as in dirty or wet
conditions, to purge water or dirt contamination from grease fittings and other critical
components.
J Dealer service item.
123
Maintenance
Periodic Maintenance Schedule
Item to Inspect Hours/
Miles
Frequency Remarks
Brake System Pre-ride Pre-ride Inspect
Tires Pre-ride Pre-ride Inspect
Wheels Pre-ride Pre-ride Inspect
Frame nuts, bolts,
fasteners
Pre-ride Pre-ride Inspect; tighten any loose hardware
Throttle Pre-ride Pre-ride Check for proper operation
Engine stop switch Pre-ride Pre-ride Check for proper operation
Engine oil Pre-ride Pre-ride Check level; fill oil when refueling
" Air Filter Pre-ride Pre-ride Inspect; clean
" Steering Pre-ride Pre-ride Check for free operation
" Drive Chain Pre-ride Pre-ride Inspect
J Brake pad wear 10 hrs Monthly Inspect periodically
Battery 20 hrs Monthly Inspect terminals; clean
124
Maintenance
Periodic Maintenance Schedule
Item to Inspect Hours/
Miles
Frequency Remarks
Oil Pump Cable 50 hrs 6 months Inspect; adjust; lubricate; replace if
required
Carburetor Float
Bowl
50 hrs 6 months Drain bowl periodically and prior to
storage
J Throttle Cable/ETC
Switch
50 hrs 6 months Inspect; adjust; lubricate; replace if
necessary
" Steering 50 hrs 6 months Inspect; lubricate
" Rear Axle 50 hrs 6 months Inspect bearings; lubricate
" Drive Chain 50 hrs 6 months Inspect; adjust and lubricate if needed
" Front Suspension 50 hrs 6 months Inspect; lubricate; tighten fasteners
" Rear Suspension 50 hrs 6 months Inspect; tighten fasteners
J Clutches (drive and
driven)
100 hrs 12 months Inspect; clean
Engine Mounts 100 hrs 12 months Inspect
125
Maintenance
Periodic Maintenance Schedule
Item to Inspect Hours/
Miles
Frequency Remarks
Spark Plug 100 hrs 12 months Inspect; replace if necessary
J Ignition Timing 100 hrs 12 months Inspect; adjust as needed
J Fuel System 100 hrs 12 months Check for leaks at tank cap, lines, fuel
valve, filter, pump and carburetor. Replace
lines every two years.
J Fuel Filter 100 hrs 12 months Replace annually
J Front wheel bearings 300 hrs 36 months Inspect; replace if necessary
J Idle Speed As needed As needed Adjust
J Toe adjustment As needed As needed Inspect periodically adjust when parts are
replaced
126
Maintenance
Lubrication Recommendations
Item Lube Method Frequency
1. Engine Oil Polaris VES II
Synthetic 2-cycle
Fill oil tank. As needed and
when refueling
2. Gearcase Oil
Level
AGL Synthetic
gearcase lube
See Page 146. Change annually or at
100 hrs. Maintain in
SAFE range.
3. Drive Chain Polaris chain lube
or SAE 80/90
Lubricate as required
and before each ride
in wet conditions.
As required
4. Front A-Arm " L Grease Locate fittings and
grease.
Every 3 months or 50
hrs.
" Grease m ore often under severe use, such as wet or dusty conditions.
L Use Polaris Premium all Season Grease or grease conforming to NLGI No. 2.
127
Maintenance
Lubrication Recommendations
2
4
4
50cc Models90cc Models
128
Maintenance
Lubrication Recommendations
Polaris 2-Cycle Lubricants
Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically
designed for today’s 2-cycle engines. These oils provide additives for 2-cycle engines that
are lacking in today’s fuel. These additives keep ring grooves cleaner for l ess ring sticking
and improved overall engine cleanliness. We recommend the use of these oils for all
Polaris 2-cycle engines.
Polaris premium 2-cycle oils will mix with each other, but we recommend that you choose
only one of the oils and use it exclusively through the life of t he unit. Never mix Polaris
2-cycle oils with any other brand of oil, including Polaris Nature Oil Biodegradable oil.
Their incompatibility could result in engine damage. See page 166 for t he part numbers of
Polaris products.
129
Maintenance
Lubrication Recommendations
Polaris VES II Synthetic 2-Cycle Oil
Your ATV has been primed with VES II synthetic oil. We recommend the continued use of
this oil. It’s been formulated for l ow smoke, low odor, l ow deposits and high l ubricity.
Premium 2- Cycle Oil
Polaris Premium Gold Synthetic 2-Cycle Oil is also suitable for use.
130
Maintenance
Periodic Maintenan ce Record
Use the following chart to record periodic maintenance.
Maintenance
Interval
Performed
Servicing
Date
Servicing
Dealer
or Person
Remarks
First 5 hrs.
25 hrs.
50 hrs.
75 hrs.
100 hrs.
131
Maintenance
Periodic Maintenan ce Record
Maintenance
Interval
Performed
Servicing
Date
Servicing
Dealer
or Person
Remarks
132
Maintenance
Rear Spring Adjustment
The rear shock absorber spring is adjusted by rotating the
adjuster (A) in the direction required to increase or
decrease spring tension.
Handlebar Adjustment
WARNING
Improper adjustment of the handlebars or incorrect torquing of the adjuster block
tightening bolts can cause limited steering or loosening of the handlebars, resulting in
loss of control and possible serious personal injury or death. Follow the adjustment
procedures exactly, or see your Polaris dealer for service.
A
133
Maintenance
Handlebar Adjustment
The handlebars can be adjusted for rider
preference.
1. Remove the pod to access the handlebar bolts.
2. Loosen the four bolts (A).
3. Adjust the handlebar to the desired height. Be
sure the handlebars do not hit the gas tank or
any other part of the machine when turned
fully to the left or right.
4. Lightly tighten each bolt equally to prevent
uneven gaps in the block.
5. Torque the handlebar adjuster block bolts to
7.3 ft. lbs. (10 Nm).
A
134
Maintenance
Axle and Wheel Nut To rque Specifications
Check the following nuts occasionally and when they’ve been loosened for maintenance.
Specification
Front Spindle Nuts 42-45 ft. lbs. (57-61 Nm)
Rear Spindle Nuts 78-81 ft. lbs. (106-110 Nm)
NOTE: All nuts with a cotter pin installed must be serviced by an authorized Polaris
dealer.
Front 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.
135
Maintenance
Speed Cont rol Systems
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 50 cc models and under 15 MPH for
the90ccmodels.
The dealer CANNOT, under any circumstances, either prior to t he sale or later, even at the
consumer’s request, remove or adjust any speed limiting devices.
Polaris Youth ATVs have an electronic speed control system and an adjustable throttle
limiting screw. These speed limiting devices may be adjusted/removed only by consumers
when they determine that their child is capable of handling the additional speed.
Per ANSI / SVIA--1--2001 (sec. 6.2) the unrestricted top speed is less than 15 MPH for the
50 cc models and less than 30 MPH for the 90 cc models.
136
Maintenance
Speed Cont rol Systems
Electronic Speed Control System
Your Polaris ATV has a speed control system
that controls engine RPM and speed of the ATV.
Adjust speed by removing or installing the
jumper on the CDI (A). With the j umper
installed, 50cc models will travel no faster than
10 mph and 90cc models will travel no faster than
15 mph. With the jumper removed, 50cc models
will travel no faster than 15 mph and 90cc models will
travel no faster than 30 mph.
Jumper Removal and Installation
1. Remove the CDI and its rubber mounting strap from the mounting tab located on the
frame bulkhead near the steering post. It can be accessed through the left (90cc
models) or right (50cc models) front fender.
2. Remove the two screws (B) from t he jumper to remove or install t he jumper, then
reinstall the screws.
3. Reinstall the CDI and mounting strap onto the mounting t ab.
A
B
A
50cc 90cc
137
Maintenance
Speed Cont rol Systems
Throttle Stop Speed Control System
Adjusting speed at the CDI is the recommended
method of speed control, but the throttle stop system
may also be used. Use the following procedure to
control how far the throttle opens.
1. Loosen the jam nut (A)
2. Turn the screw (B) inward to reduce speed or
outward to increase speed.
3. Tighten the jam nut after adjusting.
A
B
138
Maintenance
Steering Inspectio n
The steering assembly of the ATV should be checked periodically for loose nuts and bolts.
If any are found, have your dealer tighten them before operating the ATV.
Toe Alignment
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.
Use the following procedure to check the toe alignment of the vehicle. The recommended
toe alignment is 1/8” to 1/4” 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 (A) in front of the vehicle, perpendicular to the rear tires. See illustration.
139
Maintenance
Toe Alignment
3. Tie an elastic string around the stands, making
sure the string j ust touches the side surface of the
rear tires on each side of the vehicle and goes
around the stands in front of the vehicle (2).
4. Measure the distance from the string to the rim at
the front and rear of the front rim (3). Rear
measurement should be 1/16″ -1/8″ (.2to.3cm)
more than the front measurement.
NOTE: If you discover improper alignment, see
your Polaris dealer for service.
Camber and Caster
The camber and caster are non-adjustable.
A
C
B
140
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 ″ (1.5mm - 3.2mm) (A). If adjustment is
required, turn the adjustment nut (B) until the
freeplay falls in to the acceptable limit.
Brake Freeplay
Brake Freeplay Specifications
Model Front Rear
Predator 50 .1″ -.39″ (2.5-9.9 mm) .15″ -.30″ (3.8-7.6 mm)
Predator 90 .40″ -.80″ (10-20 mm) .40″ -.80″ (10-20 mm)
Sportsman 90 .40″ -.80″ (10-20 mm) .40″ -.80″ (10-20 mm)
A
B
141
Maintenance
Brake Adjustment
Periodically check (measure) the freeplay of the front and
rear brakes (A). Refer to the specifications chart on page
140 for the acceptable range of freeplay.
To adjust the front brake freeplay, turn the adjustment
knob (B). To adjust the rear brake freeplay, turn the
adjuster nut (C).
Brake Lever Travel
Service the brakes when brake lever travel (D) reaches the
following total lever travel measurements. Always service
the brakes when there is no longer s ufficient stopping
ability at the specified lever travel setting.
Component Total Lever Travel
Front brake lever 1 3/4” (45mm)
Rear brake lever 2 1/2” (65mm)
C
B
A
D
142
Maintenance
Air Cleaner
Inspect the air filter weekly or after every 50
hours of operation. If the ATV is ridden in
wet or dusty conditions, clean the filter
more often.
1. Remove the screws (A) on the airbox
and remove the filter (B).
2. Soak the filter in a mild detergent and
rinse it in clean water.
3. Let the filter air dry and reinstall.
CAUTION
Never operate the ATV with the filter element removed. Dirt will enter the engine
causing serious rapid wear and damage to the engine.
A
B
143
Maintenance
Carburetor Adjustments
Your Polaris ATV is calibrated at the factory for optimal performance at altitudes 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 performance, overheating or
engine damage. See your Polari s dealer for more i nformation about jetting the ATV for
conditions in your area.
144
Maintenance
Spark Plugs
S Use NGK BP7HS or NGK BPR7HS spark plugs.
S Proper electrode gap is .24”-.28” (0.6-0.7 mm).
S Spark plug torque is 14 ft. lbs. (19 Nm).
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 t he 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-recommended spark plugs.
WARNING
A hot exhaust system and engine can cause serious burns. Wear protective gloves
when removing a spark plug for inspection.
145
Maintenance
Spark Plugs
NORMAL: 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 carburetion adjustments.
WET FOULED: 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 oil, improper
use of the choke, or incorrect carburetion adjustments.
Spark Plug Removal and Replacement
1. Remove the spark plug cap.
2. Using the special wrench provided in the tool pouch, rotate the spark plug
counterclockwise to remove.
3. Reverse t he procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).
146
Maintenance
Cylinder Head/Cylinder Base Fastener To rque
Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque
at the first service or after 25 hours.
Gearcase Lubrication
The gearcase fill plug (A) is located on the top
of the gearcase. The sight glass (B) is on the
righthand side of the gearcase. The oil level
must be maintained in the safe zone of the sight
glass. It should be checked monthly and
changed annually.
With the ATV on a level surface, check the oil
level through the sight glass. If the level is low,
add AGL Synthetic Gearcase Lubricant. See
page 166 for the part numbers of P olaris
products.
B
A
147
Maintenance
Gearcase Oil Change
1. Remove the fill plug.
2. Remove the gearcase drain plug and drain the oil into a drain pan. Dispose of properly.
3. Clean and reinstall the drain plug. Torque to 14 ft. l bs. (19 Nm).
4. Add AGL Synthetic Gearcase Lubricant to the safe zone in the sight glass.
Model Total Capacity Capacity at Oil Change
50cc Models 10 oz. (300 ml) 7 oz. (200 ml)
90cc Models 20.25 oz. (600 ml) 16.25 oz. (480 ml)
5. Replace the fill plug and check for leaks.
148
Maintenance
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 cm) or less.
149
Maintenance
Tire Tread Depth
Always replace tires when tread depth i s worn to
1/8″ (.3 cm) or less. See illustration.
Wheel Removal
1. Stop the engine and lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate t he side of the vehicle by placing a
suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the wheel .
1/8I (.3 cm)
150
Maintenance
Wheel Installatio n
1. With the park brake locked, 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.
2. Install the wheel bolts (A) and finger
tighten them.
3. Lower the vehicle to t he ground.
4. Securely tighten the bolts to 22 ft. lbs.
(30 Nm).
A
151
Maintenance
Drive Chain Inspection and Adju stment
Regularly lubricat e the drive chain with Polaris chain spray lube or an approved chain lube.
See page 166 for the part numbers of Polaris products.
CAUTION
W ashing 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 specifications.
152
Maintenance
Drive Chain Inspection and Adjustment (90cc Models)
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. Fasten the
strap (A) around the axle and rear bumper tube.
3. Tighten the strap until a straight
line (B) 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 (C)
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 154.
A
B
C
153
Maintenance
Drive Chain Insp ection an d Adjustment (50cc Mo dels)
1. Check the amount of chain
slack by moving the vehicle
slightly forward to gain slack
at the top side of the chain.
2. The chain should have
1/4”-1/2” (6-12 mm)
deflection. If the chain needs
adjustment, use the procedure
on page 154.
154
Maintenance
Drive Chain Slack Adjustment
CAUTION
Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the
stud.
1. Loosen the four rear housing mount
bolts (A).
2. Loosen the chain adjuster lock nut.
3. Turn the chain adjuster (B) clockwise to
1/4”-1/2” (6-12 mm) deflection.
4. Tighten the chain adjuster lock nut to
84 in. lbs. (9.4 Nm).
5. Tighten the four rear housing mount
bolts to 43 ft. lbs. (60 Nm).
A
B
A
B
C
155
Maintenance
Brakelight Lamp Replacement
If the brakelight doesn’t work, the lamp may need to be replaced.
1. From the rear of the brakelight, remove the two
screws (A) holding the lens cover in place and
remove the lens cover (B).
2. Remove the lamp (C) and replace it with a new
recommended lamp.
3. Test the brakelight to ensure operation.
4. Reinsta ll the lens cover.
Indicator L amp Replacement
1. Remove the handlebar cover or pod to access the lamps.
2. Use a needle-nose pliers to pinch the tangs and remove the lamp.
3. Apply dielectric grease to the socket and install the new lamp.
4. Reinstall the cover or pod.
156
Maintenance
Cleaning and Storage
Keeping your ATV clean will not only improve its appearance but it can also extend the life
of various components. With a few precautions, your ATV can be cleaned much like an
automobile.
W ashing the ATV
The best and safest way to clean your ATV is with a garden hose and a pail of mild soap
and water. Use a professional type washing mitten, cleaning t he upper body first and the
lower parts last. Rinse with water frequently and dry with a chamois to prevent water
spots. NOTE: If warning and safety labels are damaged, contact your a Polaris dealer for
free replacement.
Polaris does not recommend the use of a high pressure type car wash system for washing
the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to
the wheel bearings, transmission seals, body panels, brakes and warning labels.
NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for
a while to evaporate any water that may have entered the engine or exhaust system.
157
Maintenance
Cleaning and Storage
Waxing the ATV
Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of
harsh cleaners since they can scratch t he body finish.
CAUTION
Certain products, including insect repellants and chemicals, will damage plastic
surfaces. Use caution when using these products near plastic surfaces.
158
Maintenance
Cleaning and Storage
Storing the ATV
Proper preparation of the engine and fuel system is vital to the prevention of rust and
corrosion on engine parts. Whenever the machine is stored for a period of more than 60
days, the engine must be fogged. Use Polaris fogging oil and follow the directions on the
can.
Always add a fuel conditioner/stabilizer to the fuel tank before storage. Run the engine for
five minutes to get t he additives through the entire fuel system and then top off with fuel.
Fuel additive products are available through your Polaris dealer.
NOTE: Jet restriction caused by improper storage can cause lean conditions and very poor
slow speed driving quality.
159
Maintenance
Cleaning and Storage
Transporting the ATV
Follow these procedures when transporting the ATV.
1. Turn the fuel valve off.
2. Be sure the fuel cap, oil cap and seat are installed correctly and securely.
3. Tie the frame of the ATV to the transporting unit securely using suitable straps or rope.
4. Lock the parking brake.
Accessories
Polaris has a wide range of accessories available for your ATV. See your Polaris dealer.
160
Specifications
Predator 50
Rider Capacity/Maximum Weight 1 Rider/90 lbs. (41 kg)
Displacement 49cc
Carburetion H68K
Cooling Air Cooled
Engine type 2-Stroke
Lubrication Oil Injected
Oil Capacity 20 oz. (.6 liter)
Fuel Capacity 1 gallon (3.8 liters)
Starting Electric with kick-start backup
Drive System Automatic CVT
Final Drive Chain
Front Suspension Single control arm with 3″ (7.6 cm) of travel
Rear Suspension Spring over shock with 3″ (7.6 cm) of travel
161
Specifications
Predator 50
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front T ires 16 x 6.5 - 7 (3 psi)
Rear Tires 16 x 8 - 7 (3 psi)
T urning Radius (inside tire) 60″ (152 cm)
Wheel Base 33″ (84 cm)
Ground Clearance 4″ (10 cm)
Dry Weight 185 lbs. (84 kg)
Length/Width/Height 48″ (10 cm) / 31.5″ (122 cm) / 28″ (71 cm)
Brake Light Standard
Low Oil Light Standard
162
Specifications
Predator 90
Rider Capacity/Maximum Weight 1 Rider/165 lbs. (75 kg)
Displacement 89cc
Carburetion H68K
Cooling Fan Cooled
Engine type 2-Stroke
Lubrication Oil Injected
Oil Capacity 1.1 quarts (1 liter)
Fuel Capacity 1.3 gallons (5 liters)
Starting Electric with kick-start backup
Drive System Automatic CVT
Final Drive Chain
Front Suspension A-arm with 4.25″ (10.8 cm) travel
Rear Suspension Spring over shock with 5″ (12.7 cm) of travel
163
Specifications
Predator 90
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front T ires 19 x 7 - 8 (3 psi)
Rear Tires 18 x 9.5 - 8 (3 psi)
T urning Radius (inside tire) 70″ (178 cm)
Wheel Base 38.5″ (98 cm)
Ground Clearance 5″ (12.7 cm)
Dry Weight 262 lbs. (119 kg)
Length/Width/Height 57″ (145 cm) / 35.75″ (91 cm) / 36.1″ (91.8 cm)
Brake Light Standard
Low Oil Light Standard
164
Specifications
Sportsman 90
Rider Capacity/Maximum Weight 1 Rider/165 lbs. (75 kg)
Displacement 89cc
Carburetion H68K
Cooling Fan Cooled
Engine type 2-Stroke
Lubrication Oil Injected
Oil Capacity 1.1 quarts (1 liters)
Fuel Capacity 1.32 gallons (5 liters)
Starting Electric with kick-start backup
Drive System Automatic CVT
Final Drive Chain
Front Suspension A-arm with 5″ (12.7 cm) of travel
Rear Suspension Spring over shock with 4.25″ (10.8 cm) of travel
165
Specifications
Sportsman 90
Front Rack Capacity 10 lbs. (4.5 kg)
Rear Rack Capacity 20 lbs. (9 kg)
Front/Rear Brakes Drum
Parking Brake Mechanical Lock
Front T ires 19 x 7 - 8 (3 psi)
Rear Tires 18 x 9.5 - 8 (3 psi)
Wheel Base 38.5″ (98 cm)
Ground Clearance 5″ (12.7 cm)
T urning Radius (inside tire) 70″ (177 cm)
Dry Weight 276 lbs. (125 kg)
Length/Width/Height 59.75″ (151.8 cm) / 35.75″ (90.8 cm) / 36.6″ (93 cm)
Brake Light Standard
Low Oil Light Standard
166
Polaris Products
Part No. Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2874438 VES II Synthetic 2-Cycle Oil (qt.)
2871721 Premium Gold Synthetic 2-Cycle Oil (qt.)
2871098 Premium 2-Cycle Engine Oil (qt.)
Gearcase / Transmission Lubricants
2873602 Premium AGL Synthetic Gearcase Lubricant (qt.)
2871653 Premium ATV Angle Drive Fluid (8 oz.)
2871654 Premium Demand Drive Hub Fluid (8 oz.)
Coolant
2871323 60/40 Coolant (gal.)
2871534 60/40 Coolant (qt.)
167
Polaris Products
Part No. Description
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season (3 oz.)
2871322 Premium All Season Grease (3 oz. cartridge)
2871423 Premium All Season Grease (14 oz. cartridge)
2871460 Starter Drive Grease (2 oz.)
2871515 Premium U-J oint Lube (3 oz.)
2871551 Premium U-Joint Lube (14 oz.)
2871329 Dielectric Grease (Nyogelt)
2872073 Chain Lube, Aerosol (6.25 oz.)
2872348 Chain Lube, Aerosol (16 oz.)
Additives / Miscellaneous
2871326 Carbon Clean Plus (12 oz.)
2870652 Fuel Stabilizer (16 oz.)
2870990 DOT3 Brake Fluid (12 oz.)
2872893 Engine Degreaser (12 oz.)
168
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 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
Clogged fuel filter Replace the filter
Low battery voltage Rechar ge battery with .5 amp char ger
Mechanical failure See your Polaris dealer
169
Troubleshooting
Engine Doesn’t Turn Over
Possible Cause Solution
Low battery voltage Rechar ge battery with .5 amp char ger
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Engine Pings or Knocks
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
170
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
171
Troubleshooting
Engine Runs Irregularly, Stalls or Misfires
Possible W eak Spark 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 Rechar ge battery with .5 amp char ger
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
172
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
173
Troubleshooting
Engine Stops or Loses Power
Possible Cause Solution
Out of fuel Turn fuel valve to reserve, refuel
Kinked or plugged fuel vent line Inspect and replace
Water present in fuel Replace with new fuel
Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires 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 Rechar ge battery with .5 amp char ger
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
174
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 char ges for repair or replacement of defective parts which are covered by this warranty. This warranty
begins on the date of purchase. This warranty is transferrable 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. THE PUR-
CHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN
ORDER TO HAVE VALID WARRANTY ON THE ATV. No verification of registration will be sent to the pur-
chaser 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 REGISTERED WITH POLARIS.
Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation. Purchas-
ing a machine in the crate or without proper dealer set-- up will void your warranty coverage.
175
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 warran-
ty 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 material,
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 p roducts. 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 OTHERWISE. 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.
176
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 P ERIOD. 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.
177
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.
178
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 warran-
ty 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 ve-
hicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the selling
dealer ’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be autho-
rized to perform the warranty repair.
179
Warranty
EXPORTED VEHICLES
How to Get Service
If You Move:
If you move to another country, be sure to contact Polaris Customer Assistance an d 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 ve-
hicle 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: 1-763-417-8650
Canada: 1-204-925-7100
180
Index
A
Air Cleaner 142...................
Axle and Wheel Nut Torque Specs 134.
B
Battery 118-120...................
Battery Installation 120.............
Battery Removal 119...............
Battery Storage 120................
Brake Adjustment 141..............
Brake Freeplay 140................
Brake Freeplay Specifications 140.....
Brake Lever Travel 141.............
Brake Levers 22...................
Brakelight Lamp Replacemen t 155....
Brakes 78-80......................
Break-in Period 8 8-89...............
C
Camber and Caster 139.............
Carburetor Adjustments 143.........
Chain Adjustment 154..............
Choke Lever 72...................
Cleaning and Storage 156-159........
Controls 71-87....................
Cylinder Head Torque 146...........
D
Daily Pre-Ride Inspection 90.........
Drive Chain Adjustment 151-153......
Driver Warnings 47-69..............
Driving Across Hillsides 102.........
Driving Downhill 106..............
Driving in Reverse 111..............
Driving on Slippery Surf aces 98......
Driving Over Obstacles 110..........
Driving Procedure 96..............
Driving Safely 94-111..............
Driving Through Water 108..........
Driving Uphill 100................
E
Electronic Speed Control System 136..
Emission Control Systems 115.......
Engine Start Button 73..............
Engine Stop Switch 72..............
Equipment Modifications 15.........
F
Features 71-87....................
Footwell Riser 87..................
Front Wheel Hub Tightening 134.....
Fuel Filter 85.....................
F
Fuel System 83-85.................
Fuel Valve 85.....................
G
Gas Cap 21, 84...................
Gearcase Lubrication 146...........
Gearcase Oil Ch ange 147............
H
Handlebar Adjustment 133..........
Hauling Cargo 112-114..............
Horn Button 19, 72................
I
Ignition Switch 23.................
Indicator L amp Replacement 155.....
Indicator Lights 81................
K
K-Turn 104......................
Kick Start 20.....................
Kick Start Lever 86................
Know Your ATV 18-24..............
181
Index
L-M
Lights 81........................
Lubricants, 2-Cycle 128.............
Lubrication Recommendations 126-129.
Main Switch 71...................
Maintenance 116-159...............
Maintenance Chart Key 122.........
Maintenance Record 130-131.........
Maintenance Schedule 121-125.......
Making Turns 97..................
N-O
Noise Emission Control System 115...
Oil 128..........................
Oil System 82....................
Oil Tank 82......................
P
Parking Brake 79..................
Parking Brake 80.................
Parking on a Hill or Incline 107.......
Polaris Products 166-167............
Pre-Ride Check 25-27...............
PVT System 116-117...............
R
Rear Spring Adjustment 132.........
Recommended Lubricants 177.......
Riding Rules 28-31.................
S
Safety 7-15.......................
Safety Decals 34-45................
Safety Training 7..................
Seat Latch 21.....................
Shift Lever (90cc models) 20, 76......
Signal words 8....................
Spark Arrestor 115................
Spark Plug Removal 145............
Spark Plug Replacement 145.........
Spark Plugs 144-145................
Specifications 160-165..............
Speed Control Systems 135-137.......
Start Button 73....................
Starting the Engine 91-92............
Steering Inspection 138.............
Stop Switch 19, 72.................
Stopping the Engine 93.............
Storing the ATV 158...............
Symbols 8.......................
T
Table of Contents 5................
Tether Strap 23...................
Throttle 19, 74-75..................
Throttle Cable Adjustment 140.......
Throttle Stop Speed Control System 137
Tires 149........................
Toe Alignment 138-139.............
Transporting the ATV 159...........
Troubleshooting 168-173............
Turning Around on a Hill 104........
U-V
Understanding Warnings 32..........
Vehicle Identification Numbers 70....
W
Warnings 7.......................
Warranty 174-179..................
Washing the ATV 156..............
Waxing the ATV 157...............
Welco me 3-4......................
Wheel Installation 150..............
Wheel Removal 149...............
