Polaris Sportsman 90, Outlaw 90 User Manual

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Owner's Manual for Maintenance and Safety

SPORTSMAN 90

Read this manual carefully. It contains important safety information.

Adult supervision is required at all times.

Operation is prohibited for anyone under age 10.

Pantone 419C

OUTLAW 90

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.

Visit us at www.polaris.com

product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in Taiwan 2014 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9924620

Welcome

Dear Parents:

We believe your children should have the opportunity to enjoy the POLARIS riding experience along with you. We've provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV.

A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will operate the ATV takes a training course before operating the ATV. Make sure all operators understand and follow all of the instructions and warnings contained in this owner’s manual.

Never allow a child under the age of 16 to operate an ATV without adult supervision.

Children differ in skills, physical abilities and judgement. Some children may not be able to operate an ATV safely. Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely.

For your child’s safety, be sure your child can reach and operate all ATV controls, including handlebars, brake levers, throttle lever and engine stop switch.

The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's ATV are thoroughly inspected at specific intervals. Follow all of the instructions and recommendations in this manual.

Welcome

Dear Children:

Before you ride your new POLARIS ATV, there are some important things that you need to know. You must learn how to keep yourself and those around you safe while you're riding. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner's manual. You must also take an ATV training course before you begin riding.

Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times. Never drive your ATV alone. Always make sure an adult is watching you when you ride.

Drive safely and enjoy riding your new POLARIS ATV!

Introduction. . . . . . . . . . . . . . . . . 6

Safety. . . . . . . . . . . . . . . . . . . . . . 8

Youth Section . . . . . . . . . . . . . . 39

Know Your ATV. . . . . . . . . . . 40

Pre-Ride Check. . . . . . . . . . . 47

Riding Rules . . . . . . . . . . . . . 50

Table of Contents

Adult Section. . . . . . . . . . . . . . . 55

Vehicle ID Numbers. . . . . . . . 56

Features and Controls. . . . . . 57

Operation. . . . . . . . . . . . . . . . 69

Emission Control Systems. . . 96

Maintenance . . . . . . . . . . . . . 98

Specifications. . . . . . . . . . . . 162

POLARIS Products . . . . . . . 168

Troubleshooting. . . . . . . . . . 170

Warranty . . . . . . . . . . . . . . . 176

Maintenance Log. . . . . . . . . 191

Index. . . . . . . . . . . . . . . . . . . . . 195

Introduction

Safety Words and Symbols

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

CAUTION

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

Introduction

WARNING

Failure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV.

• Never operate an ATV without proper instruction. Take a training course.

• For your child’s safety, be sure your child can reach and operate all ATV controls, including handlebars, brake levers, throttle lever and engine stop switch.

• Always follow the age guidelines for your vehicle. Y-1 0+ 90cc models are designed for children not less than 10 years of age and Y-6+ 50cc models are designed for children not less than 6 years of age. No child under the age of 16 should ride any ATV designed and sold for an adult.

• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.

Safety

Safety Training

ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course.

If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV

RiderCourse

your eligible family members. This training is included in the purchase price of your ATV.

that is available to you and

In addition, you were provided with printed material and a video or DVD that instructs operators on safe operating procedures. You should review this information with your child on a regular basis. Do not allow other children to ride this ATV unless they have read the manual, seen the instructional video or DVD and taken and completed an approved ATV safety training course.

Safety Training

If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV

RiderCourse

Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

If you purchased a POLARIS ATV outside the United States, please contact your dealer or local law enforcement agencies for information about safety training.

for a fee. Call ATV

Safety

FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www .cpsc.go v , visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.

Safety

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long Sleeves

051039

0006.31

Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Safety

Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of strong over-the-ankle boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

Safety

Equipment Modifications

Your POLA RIS vehicle is designed to provide safe operation when used as directed. WARNING! Modifying this vehicle in any way can change the top speed, stability and handling

performance of this vehicle. Modifications that increase speed, decrease stability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death. Use only POLARIS-approved accessories to modify this vehicle. Review all vehicle changes with your child prior to operating.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS-approved equipment and/or modifications have been added to the vehicle that increase speed or power.

Safety

WARNING

UNDER

Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death.

Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child's safety. Be sure to explain to your young driver that the hazards outlined in this section of the owner’s manual MUST be avoided at all times. See the RIDING RULES section and the OPERATION section of the owner’s manual for proper operating procedures.

Operator Restrictions/Age Restrictions

This vehicle is for recreational use by young operators under adult supervision ONLY.

Operation is prohibited for anyone under age 10.

Safety

Safety Warnings

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete an ATV training course. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual. See page 8.

Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course.

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Never allow a child to refuel or handle gasoline.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Turn the fuel valve off whenever the ATV is stored or parked. See page 67.

Safety

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Safety

Safety Warnings

Failure to Inspect Before Operating

Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

Protective Apparel

Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident.

Always wear an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket and long pants.

Safety Warnings

Carrying a Passenger

Carrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn. Never carry a passenger on this ATV.

Safety

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating an ATV.

Safety

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. A T V tires ar e designed fo r off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads or highways could result in a collision with another vehicle. Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.

Safety Warnings

Operating at Excessive Speeds

Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience.

Safety

Physical Control of the ATV

Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it could also contact the rear wheels.

Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

Safety

Safety Warnings

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual.

Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Safety Warnings

Improper Hill Climbing

Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 84.

Safety

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees.

>15°

Safety

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

• Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 87.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill when possible.

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 86.

Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 88.

Safety

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.

Always maintain a steady speed when climbing a hill. If all forward speed is lost If you lose all forward speed: Keep your weight uphill. Apply the

front brakes gradually (right lever). When fully stopped, apply the rear brake as well (left lever) and then lock the parking brake.

If the ATV begins rolling downhill: Keep weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the front brake slowly. When fully stopped, apply rear brake as well, and then lock the parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, follo wing the procedure described in the Owner's Manual. See page 88.

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain.

Always use extra caution on rough, slippery or loose terrain.

Safety

Safety Warnings

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

Improper Tire Maintenance

Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 81.

Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.

Safety Warnings

Improper Vehicle Modifications

Improper installation of accessories or modification of the ATV may cause changes in handling, which could cause loss of control or an accident.

Never modify the ATV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine POLARIS Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized POLARIS ATV dealer for more information.

Safety

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.

Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding.

Safety

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the footrests:

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving. The friction will help dry out the pads.

Safety Warnings

Improper Cargo Loading

Overloading the ATV or carrying/towing cargo may cause changes in handling, which could cause loss of control or an accident. Never haul cargo or tow a load with this ATV.

Never tow or pull an object behind the ATV. A wagon, sled or other towed object does not have brakes or steering. The object may overturn or collide with other objects.

Never exceed the stated load capacity for this ATV.

Safety

Safety Warnings

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the ATV and/or the operator fall through the ice. Never operate the ATV on a frozen body of water.

Operating a Damaged ATV

Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or overturn. Always remove the ignition key when the vehicle is not in use.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the ATV after driving through tall grass, weeds, brush and other tall ground cover. Promptly remove any grass or debris clinging to the vehicle.

Safety

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s). The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

Safety

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

Age Warning

WARNING Operation of this ATV by children under age 10 increases the

risk of severe injury or death. Adult supervision required for children under age 16. NEVER permit children under age 10 to operate this ATV.

Safety Labels and Locations

Operation Warning

WARNING Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear. Never use

on public roads. Never carry passengers. Never use with drugs or alcohol.

NEVER operate: without proper training or instruction; at speeds too fast for your skills or the conditions; on public roads

- a collision can occur with another vehicle; with a passenger passengers affect balance and steering and increase risk of losing control.

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns; avoid paved surfaces - pavement may seriously affect handling and control.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

Safety

Safety Labels and Locations

Discretionary Warning

WARNING Never operate this ATV on HILLS steeper than

15 degrees 15°. To prevent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill.

REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

Safety Labels and Locations

Tire Pressure Warning (OUTLA W 90)

WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

• Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa)

• Maximum Weight Capacity 180 lbs. (81.7 kg)

Tire Pressure Warning (SPORTSMAN 90)

WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.

• Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa)

• Maximum Weight Capacity 225 lbs. (102 kg)

Safety

Safety Labels and Locations

No Passenger Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in

SEVERE INJURY or DEATH.

Safety Labels and Locations

SPORTSMAN 90 Rack Warning

WARNING

• DO NOT TOW. Vehicle damage or tipover may

result causing severe injury or death.

• Maximum Rack Loads:

Front 15 lbs. (7 kg) Rear 30 lbs. (14 kg)

Safety

Safety Labels and Locations

Clutch Cover Warning

WARNING NO STEP

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

• Do not touch clutch cover, cover may become hot.

• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

Youth

Section

Know Your ATV

PARENTS: POLARIS Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experience. More information on speed limiting functions can be found beginning on page 126.

These units are not designed for adult use. Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section beginning on page 162 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.

Know Your ATV

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

1. Engine Stop Switch - When the engine is running, push this button down to shut the

engine off quickly. The button must be up before you can start the engine again.

2. Horn Button - Press the horn button to sound the horn.

3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to

go forward. Always make sure the throttle control does not stick before you drive your ATV. Read more about it on page 47.

2. Horn Button

1. Engine Stop Switch

3. Throttle Control

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 68.

5. Shift Lever - The shift lever is on the

right side of your ATV. Read about how to use the shift lever on page 62.

5. Shift Lever

4. Kick-Start Lever

6. Gas Cap - The gas cap has to be taken

6. Gas Cap

7. Seat Latch

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.

Know Your ATV

7. Seat Latch - The seat latch is under the

left edge of the seat. Reach under the left rear fender and pull back on the latch to remove the seat. To replace the seat, set it in place and push down on the seat above the latch. Always make sure the seat is locked in place before riding.

Know Your ATV

8. Rear Brakes

8. Front Brakes

8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the

ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time.

Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured. Always take your thumb off the throttle lever when you squeeze the brake levers.

Know Your ATV

10. Tether Switch

9. Ignition Switch

10. Tether Switch

9. Ignition Switch

OUTLAW

SPORTSMAN

9. Ignition Switch - The ignition switch key must be turned on before pushing the starter

button. You can also use this key to turn off the engine.

10. Tether Strap and Switch - The tether strap must always be attached snugly to your right

wrist and to your ATV every time you drive. If you fall off your ATV, the tether strap will pull away from the switch and the engine will stop.

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

Know Your ATV

Let's review the three ways to stop the engine of your A TV:

1. Push the engine stop switch down.

2. Pull the tether strap off the ATV.

3. Turn the key off.

Pre-Ride Check

W e're almost ready to have an adult start your ATV. But before the A T V is started for the first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check some things on your ATV before starting it. Let's learn about these things now.

1. Make sure the throttle doesn't stick. Check this by pushing the throttle lever toward the

handlebar and then letting go. The lever should come right back to where it was before you pushed it. If it comes back slowly or stays close to the handlebar, the ATV has a sticky throttle. This means that something is wrong or broken and must be fixed before you can ride your ATV safely.

Never start the engine if you have a sticky throttle. Y ou could be seriously hurt if you ride with a sticky throttle. Have an adult or your POLARIS dealer fix the throttle before you ride.

Pre-Ride Check

2. Make sure the brakes don't stick. Check the brake levers by squeezing them toward the

handlebar and then letting go. They should come right back to where they were before you squeezed. If they go back slowly or stay close to the handlebar, your ATV has sticky brakes. They must be fixed before you can ride your ATV safely.

Never start the engine if your ATV has sticky brakes. You could be seriously hurt if you ride with sticky brakes. Have an adult or your POLARIS dealer fix the sticky brakes before you ride.

3. Have an adult check to see if your ATV needs more gas. Children must never add their

own gasoline. This must always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 15 of this manual.

Always have an adult put gas in your ATV. Never try to do it yourself.

Pre-Ride Check

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

5. Have an adult check the engine oil level when the engine is cold. The engine is very hot

after it has been running and it can burn your skin if you touch it. Children must never check the oil on their own. An adult should always be in charge of keeping the gas and oil levels at the full marks.

6. This last check is done with the engine running. You must check to make sure that all

three ways to stop the engine of your ATV are working the way they should. Do you remember what they are? If you can't remember the three ways to stop the engine, go back to page 46 and review. Then have an adult help you start the engine. Practice stopping the engine all three ways.

Riding Rules

Now you're ready to learn about riding your POLARIS ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.

ŹThe adult with you is your teacher . Always pay attention to what your teacher says so you

can learn how to always drive safely.

Let's learn how to ride!

Always follow the safe riding rules found on the next pages. You or others around you could be seriously hurt if you don't follow the safe riding rules.

Riding Rules

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long Sleeves

ŹAlways wear the right kind of clothing and safety gear

when riding your ATV.

Helmet: Your helmet is very important for safe riding. A helmet can prevent a severe head injury .

Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you can see where you're driving.

Gloves: Wear gloves to protect your hands from sun and wind. Gloves will also protect your hands from scrapes and scratches.

Boots: Wear sturdy over-the-ankle boots to keep your feet dry . Boots will also protect your feet and ankles from scrapes and scratches.

Clothing: Make sure your clothing fits properly. If it's too small, it could keep you from moving easily when you shift your weight. If it's too big, it could hang down and get caught in a moving part. Wear long sleeves and long pants to protect your arms and legs.

Riding Rules

ŹAlways attach the tether strap to your right wrist

and to the ATV before riding.

ŹMake sure you know where you're going to drive

before your ATV is started. Make sure the area is safe all around your ATV.

ŹYour ATV is made for one person. Never carry a

passenger. A passenger will make the ATV harder to drive. You may lose control and hurt yourself and your passenger.

ŹAlways drive your ATV while sitting down. Keep

both hands on the handlebars and keep both feet on the footrests.

ŹAlways be alert and pay attention to where you're driving. Pay attention to other drivers,

and be even more careful around them because you don't know what they're going to do.

ŹNever follow another ATV too closely. You need lots of time and space to stop your ATV. ŹNever tow or pull an object behind the ATV.

Riding Rules

ŹNever ride alone. An adult should always be watching you in case you need help. Always

drive within the sight of an adult.

ŹNever ride on public trails. ŹDon't ride your ATV on roads or over railroad tracks. Your ATV makes noise that will

keep you from hearing cars, trucks or trains that may be coming towards you.

ŹDon't ride at night. Your ATV doesn't have lights that are safe for driving in the dark. ŹLearn where there are lakes, rivers, ponds and ditches in your driving area. Stay away

from them.

ŹNever ride on frozen water. You could get hurt or you could even die. All ice can be dan-

gerous!

ŹRide your ATV only where you know it is safe to drive and where you have permission to

drive. Be careful of the things around you.

ŹAlways be a polite driver. (Don’t drive through the flower garden or over the little trees

you planted!)

ŹAlways do your best to help take care of nature.

Respect your ATV;

respect your environment;

and you will earn

the respect of everyone.

Enjoy riding your new POLARIS ATV!

Adult

Section

Vehicle Identification Numbers

Engine Serial Number

VIN

Record your ATV's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ____________________________________________________________________

Frame VIN:______________________________________________________________________________

Engine Serial Number:_____________________________________________________________________

Key Number (on the key): __________________________________________________________________

Features and Controls

Main Key Switch

Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. Always remove the ignition key when the vehicle is not in use.

Key

OUTLAW SPORTSMAN

Features and Controls

Stop Switch

Choke Lever

Start Button

Horn

Engine Stop Switch

The engine will not start or run when the stop switch is down, in the OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency.

Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle. To stop the engine quickly, push the stop switch down.

Choke Lever

Use the choke to start a cold engine. Push the choke lever to the left before starting the engine. When the engine starts, gradually return the choke lever to the OFF position as the engine warms up and runs smoothly.

Features and Controls

Horn Button

Use the horn for emergencies and to let others know you’re near.

Engine Start Button

The start button is located slightly above the choke lever. Follow the Starting the Engine procedure beginning on page 76.

Features and Controls

WARNING

Throttle Controls

Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.

Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer 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.

Features and Controls

Throttle Lever

Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released.

This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop and power to the rear wheels will cease.

WARNING! The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the ETC system or replace it with any after market throttle mechanism. Always ensure that the throttle cable is installed and properly routed to the throttle control.

Throttle Lever

Features and Controls

Shift Lever

To change gears, stop the ATV. With the engine idling, move the lever to the desired gear. Do not try to shift gears with engine speed above idle or while the ATV is moving.

Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.

Shift Pattern

F: Forward Gear N: Neutral R: Reverse

NOTICE: Do not attempt to shift the transmi ssion

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.

Features and Controls

Rear Brakes

Front Brakes

Brakes

Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes.

WARNING! Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time.

Features and Controls

Locked

Not Locked

Brakes

Parking Brake

1. Squeeze the left brake lever.

2. Push the parking brake lock down to lock

the brake lever in place.

3. Release the brake lever.

4. To release the parking brake lock,

squeeze and release the brake lever. The parking brake will release automatically.

5. Always lock the parking brake whenever the vehicle is left unattended.

WARNING! Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage. Always be sure to disengage the parking brake before operating the ATV.

Features and Controls

WARNING

Neutral

Reverse

Neutral

OUTLAW SPORTSMAN

Lights

POLARIS Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visibility. This ATV is designed for off-road use only. Do not operate this ATV on streets or highways.

Indicator Lights

Indicator lights on the ATV let you know when your ATV is in neutral or reverse.

Features and Controls

Fuel System

Gas Cap

The fuel tank filler cap is located directly below the handlebars.

Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See page 168 for the part numbers of POLARIS products.

Use unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Nonethanol fuel is recommended. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

Refer to the specifications section beginning on page 162 for fuel tank capacity.

Gas Cap

Fuel Valve

The fuel valve is located on the left side of the ATV. It has three settings.

OFF: For vehicle storage and when transporting.

ON: For normal operation. RES: For reserve supply if main supply

is exhausted.

The reserve setting allows operation for approximately 7-10 miles (11-16 km). Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.

Features and Controls

SPORTSMAN 90 Fuel Valve

OUTLAW 90 Fuel Valve

OFF RESON

Features and Controls

Kick-Start Lever

If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced.

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

3. Lock the parking brake.

4. Fold out the kick-start lever on the left side of the ATV.

Tip: A 10/12mm wrench is provided in the tool kit for removing or

installing the lever. If not installed, make sure the rubber cap is on the kick-start shaft to protect the rider. Store the lever under the seat when it’s not installed.

5. Turn the fuel valve on.

6. Push the engine stop switch up to the ON position.

7. Turn the key to ON.

8. Place your foot on the kick-start, then thrust your heel

downward to crank the engine.

9. After the engine has started, fold the kick-start lever back into place.

Operation

WARNING

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-in Period

The break-in period for your new POLARIS 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Operation

Break-in Period

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling

gasoline. See page 15.

2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the

proper range. See page 109.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with

operation and handling.

4. Vary throttle positions. Do not operate at sustained idle.

Operation

Break-in Period

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride

inspection checklist. See page 72.

6. Perform the following maintenance at the end of the break-in period.

Item End of Break-In Remarks

Engine oil change Perform break-in oil change 110 Oil pre-filter screen Clean filter with oil change 111 Transmission oil Perform break-in oil change 114 Valve clearance See your dealer for inspection and adjustment --

See

Page

Operation

Pre-Ride Inspection

Pre-Ride Checklist

Item Remarks Page

Brake system / lever travel Ensure proper operation 129, 133 Front suspension Inspect, lubricate if necessary 106 Rear suspension Inspect, lubricate if necessary 106 Steering Ensure free operation, lubricate if necessary 134, 136 Tires Check condition and pressure 143 Wheels / fasteners Inspect, ensure fastener tightness; check that

axle nuts are secured by cotter pins

Fuel and oil Check and fill as needed 15, 66

145, 146

Operation

Pre-Ride Inspection

Pre-Ride Checklist

Item Remarks Page

Throttle Check for proper operation 47, 60, 61 Engine stop switch Check for proper function 58 Daytime running lights (if equipped) Check for proper operation 149 Brakelight Check for proper operation 147 Air filter, pre-filter Inspect, clean or replace 140 Drive chain Check condition and slack; refer to drive

chain adjustment Frame nuts, bolts, fasteners Inspect, ensure tightness -Loose or damaged components Visually inspect for any damaged compo-

nents or loose fasteners Riding gear Wear helmet, goggles, protective clothing 10

137

Operation

Safe Operation Practices

1. Complete the recommended safety training before operating this vehicle. See page 8.

2. Do not allow anyone under age 10 to operate this vehicle.

3. Never carry a passenger on this ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

5. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

6. Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories and loads on the racks (if equipped). The combined weight of these items must not exceed the maximum weight capacity.

Safe Operation Practices

7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating an ATV.

9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.

Operation

10. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.

11. Never operate the ATV on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

Operation

Full Choke

Choke Off

Starting the Engine

NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine

1. Shift the transmission to neutral.

2. Lock the parking brake.

3. Turn the fuel valve on.

4. Sit on the vehicle. Attach the tether strap to

5. If the engine is cold, use full choke by

Tip: The choke is fully on when the lever is pushed completely to the left. The choke is off when the

6. Push the engine stop switch up to the ON position.

to warm up for several minutes before operating.

the ATV and to your wrist. pushing the choke lever all the way to the

left. A warm engine will not require the use of the choke.

lever is pushed completely to the right. The choke can be adjusted gradually, depending on how much choke is needed for starting.

Operation

Starting the Engine

7. Turn the ignition key to ON.

8. Squeeze the rear brake lever and press the starter button. The rear brake lever must be engaged or the engine won't start.

9. Do not press the throttle while starting the engine. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn't start, release the starter, wait five seconds, then activate for another five seconds. Repeat until the engine starts.

10. If the engine slows or stops, position the choke lever half way to allow proper engine warm up. Vary the RPM slightly with the throttle to aid in warm up.

11. When the engine idles smoothly, push the choke lever all the way to the right.

Operation

Stopping the Engine

1. Release the throttle completely.

2. Apply the brakes until the vehicle stops moving.

3. Shift the transmission to neutral.

4. Stop the engine. There are three ways to stop the engine:

• Turn the key off.

• Push the engine stop switch down.

• Pull the tether strap off the ATV.

5. Lock the parking brake.

6. T o avoid draining the battery, always turn the key to the OFF position when the engine is not running.

Operation

Driving Procedure

1. Sit upright with both feet on the footrests and both hands on the handlebars.

2. Shift the transmission to neutral.

3. Start the engine and allow it to warm up.

4. Check your surroundings and determine your path of travel.

5. Squeeze the left brake lever.

6. Shift the transmission to the desired gear.

7. Slowly release the brake lever.

8. Slowly press the throttle with your right thumb and begin driving.

9. Drive slowly at first. Practice turning and using the throttle and brakes on level surfaces.

Operation

Making Turns

Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

To turn, steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly.

Practice making turns at slow speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

Operation

Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

Operation

Driving on Slippery Surfaces

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

Sideways skid Turn in direction of

skid

Operation

Driving Uphill

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (15° maximum).

3. Always check the terrain carefully before ascending any hill.

4. Never climb hills with excessively slippery or loose surfaces.

15° Maximum

Operation

Driving Uphill

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards.

8. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

9. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

Operation

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight uphill while keeping your feet on the footrests.

3. If the vehicle begins to slide or tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Shift body weight uphill. Transfer your weight to the rear of the vehicle.

3. Drive straight downhill.

4. Slow down. Excessive speed when traveling downhill can cause loss of control.

5. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing.

Operation

Turning Around on a Hill

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

1. Stop the vehicle and lock the parking brake while keeping body weight uphill.

2. Shift the transmission to neutral.

3. Shut off the engine.

4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

5. Staying uphill of the ATV, turn the handlebars full left.

6. While holding the brake, release the parking brake lock and slowly release the brake, allowing the ATV to roll around to your right until it's pointing across the hill or slightly downward.

Turning Around on a Hill

7. Lock the parking brake and remount the ATV from the uphill side, keeping body weight uphill.

8. Restart the engine.

9. Squeeze the rear brake lever.

10. Shift the transmission to forward gear.

11. Release the parking brake and drive slowly , controlling speed with the rear brake, until the ATV is on more level ground.

Operation

8 ft. (2.4 m)

Operation

Parking on a Hill or Incline

Avoid parking on a hill or incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.

2. Lock the parking brake.

3. Always block the rear wheels on the downhill side as shown in the illustration.

4. Turn the fuel valve off.

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or fallen trees.

Operation

Driving Through Water

Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests. Follow these precautions when operating through water:

1. Determine water depth and current before entering water.

2. If crossing a stream, choose a crossing where both banks have gradual inclines.

3. Avoid operating through deep or fast-flowing water.

Maximum Depth

Operation

Driving Through Water

4. After driving through water, dry the brakes by applying light pressure to the levers (while moving) until braking action is normal. If you do not perform this procedure, your brakes may be ineffective.

NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating

in water deeper than the footrest level. As soon as possible, perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 98. Engine oil, gearcase oil, front and rear gearcases (if equipped) and all grease fittings need special attention.

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If th is is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 118, then see your dealer for service at the first opportunity.

Operation

WARNING

Hauling Cargo

The SPORTSMAN 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling cargo on the following pages. Never carry cargo on the OUTLAW 90.

Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control, which can result in serious injury or death. Always follow these precautions when hauling cargo:

• Place 1/3 of the cargo weight on the front rack and 2/3 on the rear rack. Carrying loads on only one rack increases the chance of a tipover.

• Slow down. Allow more space for stopping the ATV when hauling cargo.

2/3 1/3

Operation

Hauling Cargo

• Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section

beginning on page 162.

• Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or

a tipover. Use suitable tie-downs or rope to secure the cargo. Do not allow cargo or tie straps to hang over the edges of the racks.

• Carry only small loads that fit on the racks. Tall loads raise the center of gravity of the vehicle and

may cause loss of control or a tipover.

• Never allow a person to ride on the racks.

• Never tow or pull an object behind the ATV . A wagon, sled or other object towed behind an A TV does

not have brakes or steering. The object may overturn or collide with other objects and cause serious injuries.

Emission Control Systems

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Emission Control Systems

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at POLARIS specifications to achieve optimal performance.

Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjustments should be performed by an authorized POLARIS dealer.

The emissions label is located on the clutch cover or engine case near the clutch box. The installation of devices that effectively increase exhaust emissions beyond their legal limits will void all man-

ufacturer warranties and may violate laws governing the registration and operation of this vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active

implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

Maintenance

Periodic Maintenance Chart

To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat.

Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Record maintenance and service in the Maintenance Log beginning on page 191.

Polaris Sportsman 90, Outlaw 90 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual