Polaris Sportsman 9921483 User Manual

WARNING

The engine exhaust from this

product contains chemicals known

to the State of California to cause

cancer, birth defects or

other reproductive harm.

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

Visit us at www.polarisindustries.com

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

Printed in USA 2008 Outlaw 90/Sportsman 90 ATV Owner's Manual P/N 9921483

Welcome

Dear Parents:

We believe your children should have the opportunity to enjoy The Way Out experience along with you. We've provided this owner's manual to assist you and your children in learning about safe operation and care of your new ATV. Please review the information in this manual with any child who may operate the ATV. Help your children learn to operate the ATV with safety as a top priority. Help them also learn to show respect for our environment and for the rights of others while operating the ATV.

Children differ in skills, physical abilities and judgement. Some children may not be able to operate an ATV safely. Always supervise your child's use of the ATV, and permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely. Never allow a child to operate the ATV without adult supervision.

The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's ATV are thoroughly inspected at various intervals. For safe and enjoyable operation of the vehicle, be sure to follow all of the instructions and recommendations in this manual. If you have any questions about the ATV, contact a Polaris dealer for assistance.

Welcome

Dear Children:

Before you ride your new Polaris ATV, there are some important things that you need to know. Your parents and Polaris want you to enjoy riding your new ATV, and that's why you need to read and understand the information in your owner's manual.

Ask your parents to explain anything you don't understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times.

As the driver of the ATV, you must learn how to keep yourself and those around you safe while you're riding. So read your manual, and then enjoy riding your new Polaris ATV!

Safety. . . . . . . . . . . . . . . . . . . . . . 6

Youth Section . . . . . . . . . . . . . . 17

Know Your ATV . . . . . . . . . . . 18

Pre-Ride Check. . . . . . . . . . . 25

Riding Rules . . . . . . . . . . . . . 28

Table of Contents

Adult Section. . . . . . . . . . . . . . . 33

Safety Decals . . . . . . . . . . . . 34

Driver Warnings. . . . . . . . . . . 43

Vehicle ID Numbers. . . . . . . . 66

Features and Controls . . . . . . 67

Break-in Period . . . . . . . . . . . 83

Pre-Ride Inspections . . . . . . . 85

Starting the Engine . . . . . . . . 88

Stopping the Engine . . . . . . . 91

Driving Safely . . . . . . . . . . . . 92

Emission Control . . . . . . . . . 112

Maintenance . . . . . . . . . . . . 114

Specifications . . . . . . . . . . . 178

Polaris Products . . . . . . . . . 182

Troubleshooting . . . . . . . . . . 184

Warranty . . . . . . . . . . . . . . . 190

Maintenance Log . . . . . . . . . 198

Index. . . . . . . . . . . . . . . . . . . . . 202

Safety

Understand the Warnings

Always follow the age guidelines for your ATV. Never allow a younger child to ride on or drive the ATV. Make sure all operators have completed an approved ATV safety training

course such as the SVIA RiderCourse before driving the ATV.

Know Your ATV Before Riding

Parents must help their children learn the proper and safe way to ride an ATV. Read the owner's manual with your children before starting the engine for the first time, and review it with them periodically afterwards.

and understand all warnings and the owner's manual

Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse

ble family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your age eligible family members who will be riding the ATV

to take the ATV RiderCourse

In addition, you were provided with printed material and a video or DVD that instructs operators on safe operating procedures. You should review this information with your child on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV RiderCourse Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

available to you and your eligi-

by calling ATV

Safety

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

CAUTION

The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious injury or death.

The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE:

A note will alert you to important information or instructions.

Safety

WARNING

Failure to follow the warnings in this manual can result in severe injury or death.

A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand the owner's manual and all warnings before operating a Polaris ATV.

Safety

• Read this manual and all labels carefully. Follow all operating procedures.

• Never operate an ATV without proper instruction. Take a training course. Pur- chasers of a new Polaris ATV and age eligible family members are entitled to take

the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information

on enrollment in the ATV RiderCourse

• Always follow the age guidelines for your vehicle: Y-12 90cc models are designed for children not less than 12 years of age and Y-6 50cc models are designed for children not less than 6 years of age. No child under the age of 16 should ride any ATV designed and sold for an adult.

. Contact ATV

• Do not allow other children to ride this ATV unless they have read the manual, seen the instructional video or DVD and taken and completed an approved ATV safety training course such as the ATV

RiderCourse

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

• Never operate an ATV on any public street, road or highway, including dirt or gravel roads.

• Always be sure there are no obstacles or people behind your ATV when operating in reverse. Drive slowly and avoid turning at sharp angles in reverse.

• Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

• 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.

• Never attempt jumps or other stunts.

• Never tow or pull an object behind the AT V.

Safety

• 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.

Safety

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

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

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

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

• Always follow proper procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

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

Safety

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

Safety

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

• Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (see page 106), 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.

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

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

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

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

• Never exceed the stated load capacity for an ATV.

• Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

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

only Polaris-approved accessories, and familiarize yourself with their function and effect on the ATV.

Youth

Section

Know Your ATV

PARENTS: Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider's skill and experience. More information on speed limiting functions can be found beginning on page 142.

These units are not designed for adult use. Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section beginning on page 178 for your ATV's capacity.

CHILDREN: Before you ride your new Polaris ATV, there are some important things that you need to know. Your safety and the safety of others is the most important thing to think about at all times. As the driver of the ATV, you must learn how to keep yourself and those around you safe while you're riding.

Pay attention when you see this symbol:

This is the safety alert symbol. When you see this symbol on your ATV or in this manual it means PAY ATTENTION because you could die or be seriously injured if you don't follow the instructions.

Know Your ATV

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

1. Engine Stop Switch - When the engine is running, push this button down to shut the engine off quickly. The button must be up before you can start the engine again.

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

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

go forward. Always make sure the throttle control does not stick before you drive your ATV. Read more about it on page 25.

2. Horn Button

1. Engine Stop Switch

3. Throttle Control

Know Your ATV

4. Kick-Start Lever - If your battery is too weak to start your ATV, you can push down on the kick-start lever with your foot to start the engine. Have an adult show you how it works. Read more about how to use the kick-start on page 82.

5. Shift Lever - The shift lever is on the right side of your ATV. Read about how to use the shift lever on page 72.

5. Shift Lever

4. Kick-Start Lever

6. Gas Cap - The gas cap has to be taken off when an adult puts gas in your ATV. Never take the gas cap off. Always make sure it's tightly closed.

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

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

Know Your ATV

6. Gas Cap

7. Seat Latch

Know Your ATV

8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time.

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

8. Rear Brakes

8. Front Brakes

Know Your ATV

9. Ignition Switch - The ignition switch key must be turned on before pushing the starter button. You can also use this key to turn off the engine.

10. Tether Strap and Switch - The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive. If you fall off your ATV, the tether strap will pull away from the switch and the engine will stop.

10. Tether Switch

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

OUTLAW

9. Ignition Switch

10. Tether Switch

SPORTSMAN

Know Your ATV

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

1. Push the engine stop switch down.

2. Pull the tether strap off the ATV.

3. Turn the key off.

Pre-Ride Check

We're almost ready to have an adult start your ATV. But before the ATV is started for the first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check some things on your ATV before starting it. Let's learn about these things now.

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

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

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

Pre-Ride Check

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

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

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

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

own gasoline. This must always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 78 of this manual.

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

Pre-Ride Check

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

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

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

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

three ways to stop the engine of your ATV are working the way they should. Do you remember what they are? If you can't remember the three ways to stop the engine, go back to page 24 and review. Then have an adult help you start the engine. Practice stopping the engine all three ways.

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