Polaris Sportsman 90 User Manual

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Polaris Sportsman 90 User Manual

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

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

PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride an ATV. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision.

CHILDREN: Before you ride your new Polaris ATV, there are some important things you should know. How to keep safe is the most important thing. You must also learn some things that will keep you and those around you safe while you are riding.

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ii

FOREWORD

Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATVs). It is designed to provide superior riding comfort, enjoyment, and safety.

This manual is furnished to ensure that the operator and parents are aware of safe operating procedures. It also includes information about the general care and maintenance of your ATV.

Carefully read the following pages. If you have any questions regarding this ATV contact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide you with the best service possible.

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PROTECT YOUR SPORT

Know all local, state/province riding laws; Respect your vehicle;

Respect the environment; and You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as outlined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

iv

INTRODUCTORY SAFETY MESSAGE TO PARENTS

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions.

Children differ in skills, physical abilities, and judgement. Some children may not be able to operate an ATV safely. Parents should supervise their child’s use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability and maturity to operate the ATV safely.

Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.

Read this manual and all labels carefully and follow the operating procedures described.

Never operate an ATV without proper instruction. Take a training course. Riders should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

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Always follow the age guidelines for your machine. Youth ATVs are designed and intended for use by children in two age groups. The Scrambler 50 is for children not less than 6 years of age. The Scrambler 90 and the Sportsman 90 are for children not less than 12 years of age. No children under the age of 16 should ride an ATV designed and sold for an adult.

Do not allow other children to ride this ATV unless they have read the manual, seen the instructional video and taken and passed a Polaris approved riding skill test.

Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways, parking lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

Never operate an ATV without wearing an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, longsleeved shirt or jacket, and long pants.

Never consume alcohol or drugs before or while operating this ATV.

Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.

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Never attempt wheelies, jumps or other stunts.

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 schedules described in this manual.

Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

Never operate on excessively rough, slippery or loose terrain.

Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident.

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

vii

• Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill.

Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have mastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

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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 remount, following the procedure described in this manual.

Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper

procedures when operating over obstacles as described in this manual.

Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg. 98), go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary apply them lightly several times to let friction dry out the pads.

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Always use the size and type tires specified in this manual. Always maintain proper tire pressure as described in this manual.

Never modify an ATV through improper installation or use of accessories.

Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modifications may create a substantial safety hazard.

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Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.

We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals.

NOTE:

The addition of certain accessories may change the handling characteristics of the ATV.

Be certain any accessories added to this ATV have been approved by Polaris. Familiarize yourself with their function and affect on the ATV.

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

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TABLE OF CONTENTS

RIDER’S SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1 - R-20 UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4 GENERAL SAFETY AND DESCRIPTION OF LABELS . . . . . . . . . . . . . . . . . . . . . 5-19 DAILY PRE-RIDE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21 OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46 VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-48 CONTROL AND PARTS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-69 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71 RIDING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-73 VEHICLE BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-76 CARRYING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-80 DAILY PRE-RIDE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-83 RIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-103

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TABLE OF CONTENTS

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

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RIDER’S SECTION

R--1

KNOW YOUR MACHINE

PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride an ATV. You must set boundaries and adhere to them, keeping your child’s safety foremost in your mind. Never allow your child to operate this machine without adult supervision.

Polaris Youth ATVs are equipped with an Adjustable Throttle Stop System and Exhuast System Restrictor(s) to allow adults to limit the speed of the vehicle according to the rider’s skill and experience. More information on speed limiting functions can be found on pages 134-136 in the maintenance section of this manual.

CHILDREN: Before you ride your new Polaris ATV, there are some important things you should know. How to keep safe is the most important thing. You must also learn some things that will keep you and those around you safe while you are riding.

R--2

KNOW YOUR MACHINE

Pay attention when you see this symbol.:

This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you don’t, you could get hurt very badly or even killed. Your safety is involved!

R--3

KNOW YOUR MACHINE

Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new machine.

1.Engine Stop Switch (A) - When the engine is running, you can push this button down to shut the engine off.

The button should be up “on” before starting the engine.

2.Throttle Control (B) - This makes your ATV go forward when you press it with your thumb. You must always make sure the throttle control does not stick before you operate your ATV. Read more about it on page R--12.

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A

1

B 2

 

KNOW YOUR MACHINE

3. Kick Starter (B) - If your battery is too

 

 

weak to start your machine, you can

 

push on this with your foot to start the

B

engine. Have an adult show you how

 

this works. There is more information

 

on how to use the kickstart on page

 

69.

 

3

R--5

KNOW YOUR MACHINE

4.Gas Cap - This is where the gas goes that will run your ATV. Your ATV will not run without gas. Only adults should fill the gas tank.

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Always have an adult put gas in your machine.

R--6

5.Brake Lever (C) - Squeeze this towards the handle bar to make your ATV slow down or stop. The right hand lever (C-1) controls the front brake. The left hand lever (C-2) controls the rear brake. To slow down or stop, squeeze both brake handles at the same time.

Always apply both brakes at the same time or loss of vehicle control can occur resulting in serious injury or death.

Always take your thumb off the throttle control when you pull the brake lever.

KNOW YOUR MACHINE

C-2

C-1

R--7

KNOW YOUR MACHINE

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

D

E

6

R--8

7. Tether Strap/ Switch - This must always be attached snugly to your right wrist and your machine when you are riding. If you fall off your ATV, the tether will pull off the switch and the engine will stop. Put one end of the tether strap around your right wrist. The other end must be attached to the ATV. Always attach the tether strap before you ride. (Sportsman - F and Scramblers - G)

KNOW YOUR MACHINE

F

G

7

Never ride without the tether strap attached to your right wrist and machine. Be careful not to get the cord tangled around the handlebars or any part of your body.

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KNOW YOUR MACHINE

Let’s review the three ways to stop your ATV.

1.Sliding the shut off switch to the left or right.

2.Disconnecting the tether strap will shut off the engine.

3.Turning the key to off will shut off the engine.

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KNOW YOUR MACHINE

1

R--11

PRE RIDE CHECK

You are almost ready to have an adult start your ATV. Before the ATV is started for the first time, you must do a PRE-RIDE CHECK. In fact, every time you ride your ATV you must have an adult help you check these things before starting it. Let’s learn about these things now.

Make sure the throttle doesn’t stick. Check this by pushing the lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it. If it comes back slowly or stays open, you have a sticky throttle. This means that something is wrong or broken.

If you have a sticky throttle, do not start the engine. You could get hurt if you ride when you have a sticky throttle. Have an adult or your Polaris Dealer fix the throttle.

R--12

PRE RIDE CHECK

Make sure the brakes don’t stick. Check the brake levers by squeezing

them toward the handlebar and then letting it go. They should come right back to where they were before you squeezed. If they go back slowly or stay on, your brakes are sticking.

If you have sticky brakes, do not start the engine. You could get hurt if you ride when you have sticky brakes. Have an adult or your Polaris Dealer fix the sticky brakes.

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

R--13

PRE RIDE CHECK

Have an adult check the gas level to see if your ATV needs more. Children should never add their own gasoline. This should always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owner’s Manual.

Always have an adult put gas in your machine.

Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been running. It could burn you. Children should never check the oil on their own. An adult should be in charge of keeping the gas and oil levels to the full marks.

R--14

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