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
other reproductive harm.
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
25
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.
26
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
27
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.
28
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.
30
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.
32
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.
38
: 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.
45
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.
46
HAPPEN
HAZARD
VEHICLE IDENTIFICATION NUMBERS
1
2
47
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
48
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
49
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.
50
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.
53
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.
54
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.
58
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.
59
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.
60
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.
61
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.
62
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.
64
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.
65
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