Polaris Scrambler 90, Sportsman 90 user guide

2001 YOUTH ATV MODELS
Owner’s Safety and Maintenance Manual
Read this manual carefully. It contains important safety information.
Scrambler 50 - No one under the age of 6 should ride this vehicle.
Sportsman 90 and Scrambler 90 - No one under the age of 12 should ride these vehicles.
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
Indicates a potential hazard which could result in severe in jury 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 increaqse 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 handingl and control.
Improper ATV use can result in SEVERE INJURY or DEATH
Part No. 9916424
FOREWORD
Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles(ATVs). BuiltwithAmerican engineeringand manufacturing know­how, 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.
Carefullyread the following pages. If you have any questions regarding this ATVcon­tact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide you with the best service possible.
i
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 out-
lined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.
All informationin this manual is based upon the latest productdata 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.
ii
INTRODUCTORY SAFETY MESSAGE TO PARENTS
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TOOPERATE. 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.
iii
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 allowother children to ride this ATVunless 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, drive-
ways, 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.
iv
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 unfamiliarterrain. 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 ATVcheckedbyan authorized Polarisdealerif it has beeninvolved 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.
v
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 exces­sivelyslippery 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 de-
scribed in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at highspeed. Avoid goingdown 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 turningtechnique describedin this manual on level ground. Avoid crossing the side of a steep hill if possible.
vi
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 obstaclesbefore 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 carefulofskiddingor sliding. On slippery surfaces,suchasice, go slowly and be verycautiousin order to reduce the chanceof 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.
Wetbrakesmay have reduced stopping ability. Testyour brakes after leaving water. If necessary apply them lightly several times to let friction dry out the pads.
vii
Always use the size and type tires specified in thismanual. Always maintainproper
tire pressure as described in this manual.
Never modify an ATV through improper installation or use of accessories.
Neverexceedthestatedloadcapacityfor an ATV. Cargo should be properly distrib-
uted and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY,callthe 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 o f 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;ormakeanyother modifications to the vehicle for these purposes. Anymodi­fications 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.
viii
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.
Wealsoadvise you to strictlyfollow the recommendedmaintenance programoutlined 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 in jury or death.
ix
TABLE OF CONTENTS
RIDER’S SECTION R-1 - R-20...............................................
UNDERSTANDING WARNINGS 1-4..........................................
GENERAL SAFETY AND DESCRIPTION OF LABELS 5-18.....................
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............................................................
x
TABLE OF CONTENTS
PVT SYSTEM OPERATION 104-105.......................................
BATTERY 106-111.......................................................
NOISE EMISSION CONTROL SYSTEM REGULATION 112-114...............
MAINTENANCE 1 15-161..................................................
SPECIFICATIONS 162-168................................................
WIRING DIAGRAMS 169-170.............................................
TROUBLE SHOOTING 171-172...........................................
WARRANTY 173-178.....................................................
INDEX 179-180..........................................................
xi
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.
CHILDREN: Before you ride your new Polaris AT V, 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
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. Yoursafety is involved!
KNOW YOUR MACHINE
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 - When the
engine is running, you can slide this button to the left or the right and the engine will stop. The stop switch must be in the “middle” position to start the engine again.
2. Throttle Control (A) -Thismakes 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.
RUN
OFFOFF
1
R--4
A
2
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 engine. Have an adult show you how this works. There is more information on how to use the kickstart on page
69.
KNOW YOUR MACHINE
B
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.
Always have an adult put gas in your machine.
R--6
1
4
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
5
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
KNOW YOUR MACHINE
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)
Never ride without the tether strap attached toyour right wrist and machine. Be careful not to get the cord tangled around the handlebars or any part of your body.
G
F
7
R--9
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.
R--10
KNOW YOUR MACHINE
3
1
2
R--11
PRE RIDE CHECK
You are almost ready to have an adultstart 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 thisby 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 stickythrottle. Have anadult or your PolarisDeal­er fix the throttle.
R--12
PRE RIDE CHECK
Make sure the brakes don’t stick. Check the brake levers b y squeezing
them toward the handlebar and then letting it go. They should come right back to where they were before you squeezed. Ifthey 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 ATVneeds 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 engineiscold. The engine
is very hot after it has been running. It could burn you. Children should never check the oilon their own. An adult shouldbe in charge of keeping the gas and oil levels to the full marks.
R--14
PRE RIDE CHECK
This last check is done with the engine running. You must check to make certain that ALL THREE WAYS TO STOP your ATV are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--10 and review.
R--15
RIDING RULES
Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. T he adult with you is your teacher. You must listen and pay attention or you won’t be safe when you r ide. Remember that safety while you ride is the most important thing. Let’s learn how to ride!
You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.
" Your ATV is made for one person. Never carry a passenger. A passenger
will make the ATV harder to drive. You may lose control and hurt yourself and your passenger.
" Make sureyou know where you are going to drive when your ATV isstarted.
Make sure the area is safe all around your ATV.
R--16
" Alwayswear the right kind of clothingwhen
you are riding your ATV. You will need a good helmet with a face shield or goggles. Wear a long sleeved shirt or jacket, gloves, long pants, and boots. Make sure your clothing fits properly. If it is too small, it could keep you from m oving easily. If it is too big, it could hang down and get caught in a moving part.
RIDING RULES
L
L
L
L
L
L
R--17
RIDING RULES
You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.
" Never ride alone. An adult should always be watching you in case you need
help. Always drive within the sight of an adult.
" Never ride on public trails. " Always drive your ATV while sitting down. Keep both hands on the
handlebars and keep both feet on the running boards.
R--18
RIDING RULES
" Don’t ride your ATV on roads or over railroad tracks. Your AT V makes noise
that will keep you from hearing cars, trucks or trains that may be coming towards you.
" Don’t ride at night. " 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!
" Always be alert and pay attention to where you are driving. Pay attention
to other drivers and be even more careful around them because you don’t know what they’re going to do.
R--19
RIDING RULES
" Never follow another ATV too closely. Always allow lots of time and space
to stop your ATV.
" Only ride your ATV where you know it is safe to drive. No driving over the
flower garden or on the little trees you planted. Be careful of the things around you.
" Always attach the tether strap to your right wrist and machine before riding.
Respect your ATV;
respect your environment;
and you will earn
the respect of everyone.
R--20
UNDERSTANDING WARNINGS
ATTENTION:
Always follow the age guidelines on the machine. YOU MUST MAKE CERTAIN THE OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNER’S MANUAL BEFORE OPERATION.
KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!.
It is the parent’s responsibility to teach their children the proper and safe way to ride any ATV. This should be done by reading the owner ’s manual with your children be­fore they first use the ATV and periodically afterwards.
SAFETY TRAINING.
When you purchased this vehicle your dealer presented a hands-on safety training course covering all aspects of ATV safety. In addition,you were provided with certain printed material and a video which instructsoperatorson safe operating procedures.
1
UNDERSTANDING WARNINGS
You should reviewthisinformation with your child on a regular basis. In the eventyou purchased a used Polaris ATVfroma party other than a Polarisdealer, safetytraining can obtained at no charge from any authorized Polaris dealer.
Failure to follow the warnings contained in this manual can result in severe INJURY
OR DEATH.
NOTE: Illustrations used in this manual are for general representation only. Your model may differ.
SAFETY
WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual carefully. Always follow their instructions.
2
ALERT
UNDERSTANDING WARNINGS
The following precautionary signal words are used throughout this manual to convey the following messages:
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!
Indicates a potential hazard which could result in severe in jury or death.
3
UNDERSTANDING WARNINGS
The following precautionary signal words are used throughout this manual to convey the following messages:
Indicates a poten tial hazard which may result in minor personal injury or damage to the ATV.
Indicates a situation that can result in damage to the machine.
NOTE
4
The word “NOTE:” in this manual will alert you to key information or instructions.
GENERAL SAFETY AND DESCRIPTION OF LABELS
NOTE:
Warning decals have been placed on the vehicle for the protectionof the operator(s). Read and follow the instructions on each decal carefully. In the event any decal be­comes illegible or comesoff,contactyour Polarisdealerfora replacement. Any safe­ty decal needing replacement will be provided by Polaris at no charge. The part num­ber is printed on the decal.
5
GENERAL SAFETY AND DESCRIPTION OF LABELS
WARNING
1
6
GENERAL SAFETY AND DESCRIPTION OF LABELS
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. 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 WARNINGS. IF OWNER’S MANUAL IS MISSING, CONT ACT A POLARIS DEAL­ER FOR A REPLACEMENT.
7
GENERAL SAFETY AND DESCRIPTION OF LABELS
2
2
Kids under age 6 should NEVER operate this ATV. Kids
S
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 ATV on HILLS steeper than 15 degrees
15°. To prevent flipover on hilly terrain, use throttle
and brakes gradually.
(Found on Scrambler 50)
8
SAFETY WARNING AND OPERATION DECALS
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 Training Course.
S Never operate this ATV on HILLS steeper than 15 degrees
15°. To prevent flipover on hilly terrain, use throttle
and brakes gradually.
9
SAFETY WARNING AND OPERATION DECALS
2
Kids under age 12 should NEVER operate this ATV. Kids
S
under 12 have an increased chance of losing control,which could result in severe injury or death.
Adult supervision is required.
S
Make sure operators follow Ow ner ’s Manual and labels.
S
S
Make sure operators watch the safety video and pass the ATV Training Course.
Never operate this ATV on HILLS steeper than 15 degrees
S
15°. To prevent flipover on hilly terrain, use throttle
and brakes gradually.
(Found on Scrambler 90 and Sportsman 90
10
2
7079091
GENERAL SAFETY AND DESCRIPTION OF LABELS
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 Training Course.
S Never operate this ATV on HILLS steeper than 15 degrees
15°. To prevent flipover on hilly terrain, use throttle
and brakes gradually.
11
GENERAL SAFETY AND DESCRIPTION OF LABELS
4
3
3
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 _____ LBS.
(Found on Scrambler 50 and Scrambler 90)
12
GENERAL SAFETY AND DESCRIPTION OF LABELS
4
WARNING
Indicates a potential hazard which could result in severe in jury or death.
13
GENERAL SAFETY AND DESCRIPTION OF LABELS
6
5
14
GENERAL SAFETY AND DESCRIPTION OF LABELS
D Operation of this
vehicle without the filter element will severely damage the engine.
D Clean air filter often, more
frequent cleaning required in dusty conditions.
ATTENTION
required depending on temperature and altitude. See your Owner’s Manual.
D 40° to 80° F. at 0-3000 feet. (5° to 27°
C. at 0-900 meters)
5
D Specific carburetor jetting
and adjustments are
Factory Setting:
6
(on rear of seat)
15
GENERAL SAFETY AND DESCRIPTION OF LABELS
16
8
7
9
10
GENERAL SAFETY AND DESCRIPTION OF LABELS
7
Moving parts hazard under belt-clut ch guard. To prevent serious injury, do not operate vehic le with guar d removed.
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.
WARNING
8
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.
Maximum Front Rack Load 10 lbs.
(Found on the Sportsman 90)
9
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death.
Maximum Rear Rack Load 20 lbs.
17
GENERAL SAFETY AND DESCRIPTION OF LABELS
10
MANUFACTURED BY: POLARIS IND. INC.
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.
18
S
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 423 LBS.)
S
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.
(Found on Sportsman 90)
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN 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 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.
HAPPEN
HAZARD
19
DAILY PRE -RIDE INSPECTION
This ATV must be inspected each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.
Use the following checklist to verify your machine is in proper workingordereachtime you ride.
Item/Inspection Procedure
1. Tires - check condition and pressures
2. Fuel and oil tanks - fill both tanks to their proper levels
3. All brakes - check operation, adjustment.
4. Throttle - check for free operation and closing
5. Brakelight - check for proper operation.
20
DAILY PRE -RIDE INSPECTION
6. Engine stop switch - 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 inspectvehiclefor anydamaged componentsor loosenuts/
bolts or fasteners
12. Operators helmet, goggles and clothing
Indicates a potential hazard which could result in severe in jury or death.
21
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN 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 judgmentneeded to operate the ATV safely and may be involved in a serious accident.
HOW TO AVOID THE Follow the age guidelines printed on your machine.
22
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN 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 Never carrya passenger. The long seat is to allow
the operator to shift position as needed during op­eration. It is not for carrying passengers.
HAPPEN
HAZARD
23
OPERATION WARNINGS
POTENTIAL HAZARD Operating this ATV on paved surfaces, including side-
walks, paths, parking lots, and driveways. WHAT CAN The ATV tires are designed for off-road use. Paved
surfaces may seriously affect handling and control of the ATV, and may cause the vehicleto goout ofcontrol.
HOW TO AVOID THE Avoid operating the ATV on pavement whenever pos-
sible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.
24
WARNING
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV on public streets, roads or
highways. WHAT CAN You can collide with another vehicle. HOW TO AVOID THE 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.
HAPPEN
HAZARD
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OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and pro­tective clothing.
WHAT CAN HAPPEN helmetincreases your chancesof 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 properly.
You should also wear: eye protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and long pants.
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Always wear an approved helmet which fits
Operating without an approved
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN 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 Never consume alcohol or drugs before or while driving this ATV.
HAPPEN
HAZARD
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OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN Increases your chances of losing control of the ATV, which can result in an acci-
dent. HOW TO AVOID THE Always travel at a speed which is proper for the terrain, visibility and operating
conditions; and your experience.
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HAPPEN
HAZARD
Indicates a potential hazard which could result in severe inju ry or d eath.
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN Increases the chance of an accident, including an
overturn. HOW TO AVOID THE Never attempt stunts, such as wheelies or jumps.
Don’t try to show off.
HAPPEN
HAZARD
29
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE 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.
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HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN 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 Always keep both hands on the handlebars and both feet on the footrests of
your ATV during operation.
HAPPEN
HAZARD
31
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Failure to use extra care when operating this ATV
on unfamiliar terrain. WHAT CAN 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 Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.
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HAZARD
HAPPEN
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Failure to use extra care when operating on
excessively rough, slippery or loose terrain. WHAT CAN Could cause loss of traction or vehicle control,
which could result in an accident, including an overturn.
HAPPEN
HOW TO AVOID THE
Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
Always be especially cautious on these kinds of terrain.
HAZARD
33
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Turning improperly. WHAT CAN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE Always follow proper procedures for turning as described in the Owner’s
Manual. See page 86 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
34
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Could cause loss of control or cause ATV to over-
turn. HOW TO AVOID THE Always follow proper procedures for climbing hills
as described in the Owner’s Manual. See pages 91 through 96. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces.Shiftyour weight for-
ward. Never open the throttle suddenly. The ATV could flip over backwards. Nevergo
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.
HAPPEN
HAZARD
35
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Going down a hill improperly. WHAT CAN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE
Always follow proper procedures for going down hills as described in the Owner ’s Manual. See page 94. 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.
Avoidgoing down a hill at an angle which would cause the vehicleto leansharply to one side. Go straight down the hill where possible.
36
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE
Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground. See page 96. Be very careful when turning on any hill.
Avoid crossing the side of a steep hill if possible. When crossing the side of a hill:
in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.
HAPPEN
HAZARD
Always follow proper procedures as described
37
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Stalling, rolling backwards or improperly dismount-
ing while climbing a hill. WHAT CAN HAPPEN
ing. HOW TO AVOID THE Maintain steady speed when climbing a h ill. If you lose all forwardspeed
ply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards
Never apply the rear brake while rolling backwards. Apply the front brake slowly by squeezing the RH lever. When fully stopped, apply rear brake as well, and then lock 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 96.
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: Keep weight uphill; never apply engine power.
Could result in ATV overturn-
HAZARD
: Keep weight uphill. Ap-
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Skidding or sliding. WHAT CAN You may lose control of the ATV. You may also regaintraction unexpectedly, which maycause the ATV to over-
turn. HOW TO AVOID THE 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.
HAPPEN
HAZARD
Indicates a potential hazard which could result in severe in jury or death.
39
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or
fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in
the Owner’s Manual.
40
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN Severe injury or death can result if the ATV and/or the operator break
through the ice. HOW TO AVOID THE Never ride your ATV on a frozen body of water.
HAPPEN
HAZARD
41
OPERATION WARNINGS
WARNING
POTENTIALHAZARD OperatingthisATV throughdeeporfast flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control, which could lead
to an accident. HOW TO AVOID THE Avoidoperating the ATVthrough deep or fast flowingwater. Ifyou canotavoid
water which exceeds the recommended maximum depth, 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. See page 98.
Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let fric­tion dry out the pads.
42
HAPPEN
HAZARD
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD OperatingthisATVwith impropertires, or withimproper oruneventirepressure. WHAT CAN Use of improper tires on this ATV, or operation of this ATV with improper or un-
even tire pressure, may cause loss of control, and increases the riskof an acci­dent.
HOW TO AVOID THE Alwaysusethesizeandtypetiresspecified in the Owner’s Manual Supplement
for this vehicle. Always maintainpropertire pressureas described in the Owner’s Manual Sup-
plement.
HAPPEN
HAZARD
43
OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Overloading this ATV WHAT CAN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.
44
HAPPEN
HAZARD
OPERATION WARNINGS
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.
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.
Indicates a potential hazard which could result in severe in jury or death.
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OPERATION WARNINGS
WARNING
POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN Improper installation of accessories or modification of this vehicle maycause
changes in handling which in some situations could lead to an accident. HOW TO AVOID THE Never modify this ATV through improper installation or use of accessories.
All parts and accessories added to this vehicle should be genuine Polaris In­dustries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.
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HAPPEN
HAZARD
VEHICLE IDENTIFICATION NUMBERS
1
2
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VEHICLE IDENTIFICATION NUMBERS
y
f
y
Record these numbersfrom yourATV in the spaces provided.
1. Engine Serial Number (Left side of engine crankcase)
2. Frame VIN (found on the front of frame below steering post)
Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with yourexisting key.
The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recover
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and identification o
ourATV.
Engine Electrical Switches
CONTROL AND PARTS FUNCTIONS
1 - Main Switch
- Located on the Right-hand side of the Scram­blers (A) and on the pod of the Sportsman (B). This switch is operated with a key and must be turned clock­wise to the “on” position to start the engine.
A
B
1
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CONTROL AND PARTS FUNCTIONS
2 - Emergency Engine Stop Switch The
engine will not start or run when the switch is in its “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, slide the stop switch right or left to the “off” position.
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RUN
OFFOFF
2
CONTROL AND PARTS FUNCTIONS
3 - Engine Start Button -Tostart
the engine, make certain the tether switch is securely plugged into the machine and attached to the rider’s right wrist. Turn the key to the “on” position, set the parking brake, and push the start button.
NOTE: Remember to release the park brake before driving forward.
3
51
CONTROL AND PARTS FUNCTIONS
Engine or driveline damage could occur if the machine is driven without the park brake released.
This ATV is not equipped with lighting. This ATV is 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 machine after dark.
52
CONTROL AND PARTS FUNCTIONS
Engine Throttle
Indicates a potential hazard which could result in severe in jury or death.
Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death.
Always contact your dealer for service repairs whenever throttle problems arise.
Failure to check or maintain proper operation of the throttle system can re­sult in the throttle lever sticking during riding and cause an accident.
Always check the lever for free movement and return before starting the en­gine and occasionally during riding.
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CONTROL AND PARTS FUNCTIONS
Throttle Lever
Engine speed and vehicle movement are con­trolled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is re­leased.
This vehicle is equipped with an Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the opera­tor releases the throttle lever.
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1
CONTROL AND PARTS FUNCTIONS
The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is p rovided for your safety. Do not at­tempt to mod ify the ETC system or replace it with any after market throttle mechanism.
55
CONTROL AND PARTS FUNCTIONS
Switches
Each Polaris ATV has a main switch. It is located on the right hand side of the machine or headlight pod and operated with a key.
Indicator Lights
Each Polaris ATV has indicator lights. This model has a low oil warning light. When this red dot is lit, it is indicating a low oil level.
56
Front and Rear Brakes
To activate the rear brake (A), squeeze the left hand lever to­ward the handlebar.
CONTROL AND PARTS FUNCTIONS
The front brakes (B) are activated by squeezing the lever on the RH handlebar.
Always apply both brakes at the same time or loss of vehicle con­trol can occur resulting in seri­ous injury or death.
B
A
57
CONTROL AND PARTS FUNCTIONS
Parking Brake
Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the park­ing brake is left on while the ATV is operated.
Setting the Parking Brake
1. Squeeze the left hand brake lever (A).
2. Push the park brake lock (B) down. This willpre­vent the lever from returning to the released position.
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A
B
CONTROL AND PARTS FUNCTIONS
3. To release the parking brake lock, squeeze the brake lever. The parking brakewill release automatically.
Important Safeguards
NOTE: This vehicle has a PVT system which is always in forward. Always lock the
park brake before starting the engine. Always lock the parking brake whenever the vehicle is left unattended. Before starting the engine, make certain the park brake is fully locked. Since the
machine has a transmission that is always in forward, throttle activation to warm the engine will make the machine go forward if the park brake is not locked.
Once the engine has warmed enough for operation, release the park brake and gently apply the throttle to go forward.
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CONTROL AND PARTS FUNCTIONS
Gasoline is highly flammable and explosive under certain conditions.
D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well ventilated
area.
D Do not smoke or allow open flames or sparks in or near the area where re-
fueling is performed or where gasoline is stored.
D Do not over fill the tank. Do not fill the tank neck. D If you get gasoline on your skin or clothing, immediately wash it off with
soap and water and change clothing.
D Never start the engine or let it run in an enclosed area. Gasoline powered
engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.
D Shut off fuel valve whenever the ATV is stored or parked.
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CONTROL AND PARTS FUNCTIONS
Indicates a potential hazard which could result in severe in ju ry or death.
WARNING
The engine exhaust from this prod-
uct contains chemicals known to
cause cancer, birth defects or other
reproductive harm.
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CONTROL AND PARTS FUNCTIONS
PVT System
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:
D 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.
D Routine maintenance is the responsibility of the owner. Always follow rec-
ommended maintenance procedures. See your dealer!
D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation.
Failure to comply with this warning can result in severe injury or death.
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Engine Fuel and Oil System
Fuel System
CONTROL AND PARTS FUNCTIONS
The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a ca­pacity of 1.3 gallons (5 liters). Use un­leaded gasoline with a minimum pump oc­tane number of 87 octane.
1
63
CONTROL AND PARTS FUNCTIONS
The fuel valve is located on the engine, be­hind the right front fender and has three positions:
OFF: For vehicle storage and whenever transporting.
ON: For normal operation. RES: For reserve supply in the event of
main supply exhaustion. NOTE: There is about a 7 to 10 mile (11.2
to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply.
Always return valve to “on” position after refueling machine.
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Scrambler Fuel Valve
Sportsman Fuel Valve
CONTROL AND PARTS FUNCTIONS
Engine Fuel Safety/Fuel/Filter
The Polaris 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.
Use only Polaris injection oil. Never substitute or mix oil brands. Serious en­gine damage and voiding of warranty can result.
To avoid serious engine damage always top off the oil level when refueling.
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