Polaris Sportsman 9922475 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.

Pantone 426C

WARNING

Improper vehicle use can result in

SEVERE INJURY or DEATH.

ALWAYS USE

AN APPROVED

HELMET AND PROTECTIVE

GEAR

NEVER USE

ON PUBLIC

ROADS

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

NEVER CARRY

PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922475 Rev 02 Printed in USA

NEVER operate:

S without proper training or instruction S at speeds too fast for your skills or the conditions S on public roads - a collision can occur with

another vehicle S with a passenger - passengers affect balance

and steering and increase risk of losing control

ALWAYS:

S use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

S avoid paved surfaces - pavement may seriously affect handling and control

Visit us at www.polarisindustries.com

POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product

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

Printed in USA 2010 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9922475

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.

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

Help them also learn to show respect for our environment and for the rights of others while operating the ATV.

Never allow a child under the age of 16 to operate an ATV without adult supervision. Children differ in skills, physical abilities and judgement. Some children may not be able to operate an ATV safely. Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely.

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

Welcome

Dear Children:

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

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

Drive safely and enjoy riding your new Polaris ATV!

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

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

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

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

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

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

Table of Contents

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

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

Features and Controls . . . . . . 57

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

Emission Control Systems. . . 96

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

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

Polaris Products . . . . . . . . . 166

Troubleshooting . . . . . . . . . . 168

Declaration of Conformity . . 174

Warranty . . . . . . . . . . . . . . . 177

Maintenance Log . . . . . . . . . 189

Index. . . . . . . . . . . . . . . . . . . . . 193

Introduction

Safety Words and Symbols

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

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

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

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

Introduction

WARNING

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

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

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

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

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

Safety

Safety Training

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

If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorized ATV

RiderCourse

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

that is available to you and

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

Safety Training

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

RiderCoursesm for a fee. Call ATV

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

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

Safety

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1800-342-3764.

Safety

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long Sleeves

051039

0006.31

Riding Gear

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

Helmet

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

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

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

Safety

Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Safety

Equipment Modifications

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.

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.

Safety

WARNING

UNDER

Safety Warnings

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

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

Operator Restrictions/Age Restrictions

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

Operation is prohibited for anyone age 12 and under.

Safety

Safety Warnings

Operating Without Instruction

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

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

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

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Never allow a child to refuel or handle gasoline.

• Always exercise extreme caution whenever handling gasoline.

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

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

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

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

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

Safety

Exposure to Exhaust

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

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

Safety

Safety Warnings

Failure to Inspect Before Operating

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

Protective Apparel

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

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

Safety Warnings

Carrying a Passenger

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

Safety

Using Alcohol or Drugs

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

Safety

Safety Warnings

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

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

Safety Warnings

Operating at Excessive Speeds

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

Safety

Physical Control of the ATV

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

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

Safety

Safety Warnings

Turning Improperly

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

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

Jumps and Stunts

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

Safety Warnings

>15°

Improper Hill Climbing

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

Safety

Operating on Steep Hills

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

Safety

Safety Warnings

Descending Hills Improperly

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

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

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

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

Safety Warnings

Crossing Hillsides

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

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

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

Safety

Safety Warnings

Stalling While Climbing a Hill

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

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

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

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

Safety Warnings

Operating on Slippery Terrain

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

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

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

Safety

Safety Warnings

Operating in Unfamiliar Terrain

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

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

Improper Tire Maintenance

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

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

Operating Improperly in Reverse

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

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

Safety Warnings

Improper Vehicle Modifications

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

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

Safety

Operating Over Obstacles

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

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

Skidding or Sliding

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

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