Polaris Sportsman 90 User Manual
WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.
Indicates a potential hazard which
could result in severe injury or death.
PARENTS: Review the information in this manual with any child who may be
operating the ATV. It is up to you to teach your child the proper and safe way
to ride an ATV. You must set boundaries and adhere to them, keeping your
child’s safety foremost in your mind. Never allow your child to operate this
machine without adult supervision.
CHILDREN: Before you ride your new Polaris ATV, there are some important
things you should know. How to keep safe is the most important thing. You
must alsolearn some things that willkeep youand those around you safe while
you are riding.
i
ii
FOREWORD
Congratulations and thank you from Polaris Industries Inc. for purchasing one of our
all-terrain vehicles (ATVs). It is designed to provide superior riding comfort, enjoyment, and safety.
This manual is furnished to ensure that the operator and parents are aware of safe
operating procedures. It also includes information about the general care and maintenance of your ATV.
Carefullyreadthe following pages. If youhave any questions regardingthis ATVcontact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge
and facilities to provide you with the best service possible.
iii
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 programas out-
lined. This preventive maintenance program is designed to ensure that all critical
components on this ATV are thoroughly inspected at various intervals.
All information in this manual is based upon the latestproduct data and specifications
available at the time of printing. Polaris Industries Inc. reserves the right to make
product changes and improvements which may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written permission of
Polaris Industries Inc.
Illustrations included in this manual are general representations of parts
having a similar function. Your model may differ.
iv
INTRODUCTORY SAFETY MESSAGE TO PARENTS
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATVhandles
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
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.
if they determine that the child
v
• 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 ATV unless they have read the manual, seen
the instructional video and taken and passed a Polaris approved riding skill test.
• Always avoid operating an ATV on any paved surfaces, including sidewalks, 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.
vi
• Never attempt wheelies, jumps or other stunts.
• Always inspect your ATV each time you use it to make sure it is in safe operating
condition. Always follow the inspection and maintenance procedures and schedules described in this manual.
• Always keep both hands on the handlebars and both feet on the footrests of the
ATV during operation.
• Always go slowly and be extra careful when operating on unfamiliar terrain. Always
be alert to changing terrain conditions when operating the ATV.
• Never operate on excessively rough, slippery or loose terrain.
• Always follow proper procedures for turning as described in this manual. Practice
turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.
• Alwayshave theATVchecked by an authorizedPolaris dealerif it has been involved
in an accident.
• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice
on smaller hills before attempting larger hills.
vii
• Always follow proper procedures for climbing hills as described in this manual.
Check the terrain carefully before you start up any hill. Never climb hills with excessivelyslippery or loose surfaces. Shift yourweight 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 high speed. Avoid going down
a hill at an angle which would cause the vehicle to lean sharply to one side. Go
straight down the hill where possible.
• Always follow proper procedures for crossing the side of a hill as described in this
manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight
to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until
you have mastered the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.
viii
• Always use proper procedures if you stall or roll backwards when climbing a hill.
To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual. Dismount on the uphill side or to either side if pointed straight uphill. Turn the ATV
around and remount, following the procedure described in this manual.
• Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always follow proper
procedures when operating over obstacles as described in this manual.
• Always be carefulof skiddingor sliding. On slippery surfaces, such as ice, go slowly
and be very cautious in order to reduce the chance of skiddingor 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. Test your brakes after leaving water.
If necessary apply them lightly several times to let friction dry out the pads.
ix
• Always use the size and type tiresspecified in this manual. Always maintainproper
tire pressure as described in this manual.
• Never modify an ATV through improper installation or use of accessories.
• Neverexceed the stated load capacity for an ATV. Cargo should be properlydistrib-
uted and securely attached. Reduce speed and follow instructions in this manual
for carrying cargo. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the ConsumerProduct Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
Additional Important Information...
Due to our concern for the safety of our customers and the general public, Polaris
hereby strongly recommends and requests that consumers not have installed on a
Polaris ATV any equipment which is intended to increase the speed or power of the
vehicle;ormake any other modificationsto the vehicle for these purposes. Any modifications to the original equipment of the ATV substantially increase the risk of bodily
injury. Please be aware that these modifications may create a substantial safetyhazard.
x
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.
Wealso advise you to strictlyfollowthe 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 ju ry or death.
xi
TABLE OF CONTENTS
RIDER’S SECTION R-1 - R-20...............................................
UNDERSTANDING WARNINGS 1 - 4........................................
GENERAL SAFETY AND DESCRIPTION OF LABELS 5-19.....................
DAILY PRE-RIDE CHECK 20-21.............................................
OPERATION WARNINGS 22-46.............................................
VEHICLE IDENTIFICATION NUMBERS 47-48.................................
CONTROL AND PARTS FUNCTIONS 49-69..................................
STARTING THE ENGINE 70-71.............................................
RIDING GEAR 72-73.......................................................
VEHICLE BREAK IN PERIOD 74-76.........................................
CARRYING LOADS 77-80..................................................
DAILY PRE-RIDE CHECK 81-83.............................................
RIDING 84-103............................................................
xii
TABLE OF CONTENTS
PVT SYSTEM OPERATION 104-105.......................................
BATTERY 106-111.......................................................
NOISE EMISSION CONTROL SYSTEM REGULATION 112-114...............
MAINTENANCE 1 15-163..................................................
SPECIFICATIONS 164-170................................................
WIRING DIAGRAMS 171-172.............................................
TROUBLE SHOOTING 173-174...........................................
WARRANTY 175-180.....................................................
INDEX -................................................................
xiii
RIDER’S SECTION
R--1
KNOW YOUR MACHINE
PARENTS: Review the information in this manual with any child who may be
operating the ATV. It is up to you to teach your child the proper and safe way
to ride an ATV. You must set boundaries and adhere to them, keeping your
child’s safety foremost in your mind. Never allow your child to operate this
machine without adult supervision.
Polaris Youth ATVs are equipped with an Adjustable Throttle Stop System and
Exhuast System Restrictor(s) to allow adults to limit the speed of the vehicle
according to therider’s skilland experience. Moreinformation on speedlimiting
functions can be found on pages 134-136 in the maintenance section of this
manual.
CHILDREN: Before you r ide your new Polaris ATV, there are some important
things you should know. How to keep safe is the m ost 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. Your safety 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 (A) - When the
engine is running, you can push this
button down to shut the engine off.
The button should be up “on” before
starting the engine.
2. Throttle Control (B) -This makes your
ATV go forward when you press it with
your thumb. You must always make
sure the throttle control does not stick
before you operate your ATV. Read
more about it on page R--12.
A
1
R--4
B
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 L ever (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
F
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
G
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 withoutthe tether strap attached to your right wrist and machine.
Be careful not to get the cord tangled around the handlebars or any part
of your body.
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 adult start your ATV. Before the ATV is started
for the first time, you must do a PRE-RIDE CHECK. In fact, every time you ride
your ATV you must have an adult help you check these things before starting
it. Let’s learn about these things now.
Make sure the throttle doesn’t stick. Check this by pushing the lever toward
the handlebar and then letting go. The lever should come right back to where
it was before you pushed it. If it comes back slowly or stays open, you have
a sticky throttle. This means that something is wrong or broken.
If you have a sticky throttle, do not start the engine. You could get hurt if
you ride whenyou havea sticky throttle. Have an adult or your Polaris Dealer fix the throttle.
R--12
PRE RIDE CHECK
Make sure the brakes don’t stick. Check the brake levers by squeezing
them toward the handlebar and then letting it go. They should come right back
to where theywere before you squeezed. If they go back slowlyor 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. T his should always be done by an
adult. Before anyone adds gasoline to your AT V 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 adultcheck the engine oil level whenthe engineis cold. The engine
is very hot after it has been running. It could burn you. Children should never
check the oil on their own. An adult should be in charge of keeping the gas and
oil levels to the full marks.
R--14
Loading...