Polaris Sportsman 90 Safety And Maintenance Manual
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Polaris Sportsman 90 Safety And Maintenance Manual

2002 youth atv models
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  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 3 Indicates a potential hazard which could result in severe injury or death.
  • Page 4 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 also learn some things that will keep you and those around you safe while you are riding.
  • Page 6 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, enjoy- ment, and safety. This manual is furnished to ensure that the operator and parents are aware of safe operating procedures.
  • Page 7 ATV are thoroughly inspected at various intervals. All information in this manual is based upon the latest product 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.
  • Page 8 • 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.
  • Page 9 The Scrambler 50 is for children not less than 6 years of age. The Scrambler 90 and the Sportsman 90 are for chil- dren not less than 12 years of age. No children under the age of 16 should ride an ATV designed and sold for an adult.
  • Page 10 Do not turn at ex- cessive 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...
  • Page 11 • 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 exces- sively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or make sudden gear changes.
  • Page 12 • 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. Dis- mount on the uphill side or to either side if pointed straight uphill.
  • Page 13 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;...
  • Page 14 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. We also advise you to strictly follow the recommended maintenance program outlined in this manual.

  • Page 15: Table Of Contents

    TABLE OF CONTENTS RIDER’S SECTION ..........UNDERSTANDING WARNINGS GENERAL SAFETY AND DESCRIPTION OF LABELS DAILY PRE-RIDE CHECK...

  • Page 16: Table Of Contents

    PVT SYSTEM OPERATION BATTERY ............NOISE EMISSION CONTROL SYSTEM REGULATION MAINTENANCE .

  • Page 17: Rider's Section

    RIDER’S SECTION R--1...
  • Page 18 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 the rider’s skill and experience.
  • Page 19 KNOW YOUR MACHINE 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 in- volved! R--3...
  • Page 20 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.
  • Page 21 KNOW YOUR MACHINE 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 R--5...
  • Page 22 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...
  • Page 23 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.
  • Page 24 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). R--8...
  • Page 25 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.
  • Page 26 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...
  • Page 27 KNOW YOUR MACHINE R--11...
  • Page 28 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 sticky throttle. Have an adult or your Polaris Deal- er fix the throttle.
  • Page 29 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.
  • Page 30 PRE RIDE CHECK Have an adult check the gas level to see if your ATV needs 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.
  • Page 31 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.

  • Page 32: Riding Rules

    RIDING RULES Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won’t be safe when you ride. Remember that safety while you ride is the most important thing.
  • Page 33 RIDING RULES " Always wear the right kind of clothing when 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.
  • Page 34 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.
  • Page 35 " Don’t ride your ATV on roads or over railroad tracks. Your ATV 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.
  • Page 36 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.

  • Page 37: 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.
  • Page 38 You should review this information with your child on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, safety training can obtained at no charge from any authorized Polaris dealer.
  • Page 39 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! UNDERSTANDING WARNINGS Indicates a potential hazard which could result in severe injury or death.
  • Page 40 UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: Indicates a situation that can result in damage to the machine. NOTE The word “NOTE:” in this manual will alert you to key information or instructions. Indicates a potential hazard which may re- sult in minor personal injury or damage to the ATV.
  • Page 41 Read and follow the instructions on each decal carefully. In the event any decal be- comes illegible or comes off, contact your Polaris dealer for a replacement. Any safe- ty decal needing replacement will be provided by Polaris at no charge. The part num- ber is printed on the decal.
  • Page 42 GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING...
  • Page 43 ALWAYS 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, CONTACT A POLARIS DEAL- ER FOR A REPLACEMENT.
  • Page 44 GENERAL SAFETY AND DESCRIPTION OF LABELS 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. Adult supervision is required. Make sure operators follow Owner’s Manual and labels. Make sure operators watch the safety video and pass the ATV Training Course.
  • Page 45 GENERAL SAFETY AND DESCRIPTION OF LABELS 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.
  • Page 46 Make sure operators watch the safety video and pass the ATV Training Course. 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 90 and Sportsman 90 7079091...
  • Page 47 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.
  • Page 48 GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 3 REAR 3 maximum weight capacity (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS _____ LBS.
  • Page 49 GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING Indicates a potential hazard which could result in severe injury or death.
  • Page 50 GENERAL SAFETY AND DESCRIPTION OF LABELS...
  • Page 51 GENERAL SAFETY AND DESCRIPTION OF LABELS DOperation of this vehicle without the filter element will severely dam- age the engine. DClean air filter often, more frequent cleaning required in dusty conditions. (On air filter box) ATTENTION DSpecific carburetor jetting and adjustments are required depending on temperature and altitude.
  • Page 52 GENERAL SAFETY AND DESCRIPTION OF LABELS...
  • Page 53 RPM which can result in serious injury or death. WARNING WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Maximum Rack Loads: Front 10 lbs.; Rear 20 lbs. (Found on the Sportsman 90)
  • Page 54 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) REAR 3...
  • Page 55 HOW TO AVOID THE HAZARD 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.
  • Page 56 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 working order each time you ride.
  • Page 57 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.

  • Page 58: Operation Warnings

    OPERATION WARNINGS POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN 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 judgment needed to operate the ATV safely and may be involved in a serious accident.
  • Page 59 OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN 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 HAZARD Never carry a passenger.
  • Page 60 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including side- walks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever pos- sible.
  • Page 61 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD 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 pub- lic streets, roads and highways.
  • Page 62 OPERATION WARNINGS HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly. You should also wear: eye protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and long pants. WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing.
  • Page 63 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN 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 HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 64 OPERATION WARNINGS POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions;...
  • Page 65 OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 66 OPERATION WARNINGS POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 67 OPERATION WARNINGS WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN 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.
  • Page 68 OPERATION WARNINGS HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV. WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain.
  • Page 69 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. OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain.
  • Page 70 OPERATION WARNINGS POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD 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.
  • Page 71 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. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed.
  • Page 72 OPERATION WARNINGS 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. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side.
  • Page 73 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: Always follow proper procedures as described in the Owner’s Manual.
  • Page 74 OPERATION WARNINGS Apply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. 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.
  • Page 75 POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to over- turn. HOW TO AVOID THE HAZARD 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.
  • Page 76 OPERATION WARNINGS POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 77 OPERATION WARNINGS WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water.
  • Page 78 OPERATION WARNINGS POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If you canot avoid 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...
  • Page 79 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN 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 risk of an acci- dent.
  • Page 80 OPERATION WARNINGS POTENTIAL HAZARD Overloading this ATV WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. WARNING...
  • Page 81 After a rollover or an accident, have a qualified service dealer check the com- plete machine including, but not limited to, brakes, throttle and steering for possible damage. Safe operation of this rider active vehicle requires good judgement and physi- cal skills.
  • Page 82 HOW TO AVOID THE HAZARD 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.

  • Page 83: Vehicle Identification Numbers

    VEHICLE IDENTIFICATION NUMBERS...
  • Page 84 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 your existing key.

  • Page 85: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1 - Main Switch - Located on the Right-hand side of the Scram- blers (A) and on the pod of the Sportsman (B). This switch is op- erated with a key must turned clockwise to the “on”...
  • Page 86 CONTROL AND PARTS FUNCTIONS 2 - Emergency Engine Stop Switch The en- gine 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 shut- down in case of stuck throttle or other emer- gency.
  • Page 87 CONTROL AND PARTS FUNCTIONS 3 - Engine Start Button - To start 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, push the start but- ton up to the “on”...
  • Page 88 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.
  • Page 89 CONTROL AND PARTS FUNCTIONS Engine Throttle WARNING 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.

  • Page 90: Throttle Lever

    CONTROL AND PARTS FUNCTIONS Throttle Lever Engine speed and vehicle movement are con- trolled by pressing the throttle lever. 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 re- duce the risk of a frozen or stuck throttle.
  • Page 91 CONTROL AND PARTS FUNCTIONS WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanism.

  • Page 92: Indicator Lights

    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...
  • Page 93 Front and Rear Brakes To activate the rear brake (A), squeeze the left hand lever to- ward the handlebar. The front brakes (B) are activated by squeezing the lever on the RH handlebar. WARNING Always apply both brakes at the same time or loss of vehicle con- trol can occur resulting in serious injury or death.

  • Page 94: Parking Brake

    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.
  • Page 95 CONTROL AND PARTS FUNCTIONS 3. To release the parking brake lock, squeeze the brake lever. The parking brake will 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.
  • Page 96 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.
  • Page 97 CONTROL AND PARTS FUNCTIONS Indicates a potential hazard which could result WARNING in severe injury or death. WARNING The engine exhaust from this prod- uct contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 98 D Routine maintenance is the responsibility of the owner. Always follow recommended 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.

  • Page 99: Fuel System

    CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a capac- ity of 1.3 gallons (5 liters). Use unleaded gas- oline with a minimum pump octane number of 87 octane.
  • Page 100 CONTROL AND PARTS FUNCTIONS The fuel valve is located on the engine, be- hind the right front fender and has three posi- tions: OFF: For vehicle storage and whenever transporting. ON: For normal operation. RES: For reserve supply in the event of main supply exhaustion.
  • Page 101 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 en- gine damage and voiding of warranty can result.

  • Page 102: Oil System

    CONTROL AND PARTS FUNCTIONS Oil System The oil tank (1) is located under the seat and has a capacity of 1.1 quarts (1 liter). To remove the seat, reach under the rear of the cab and pull back on the seat latch.
  • Page 103 Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Po- laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.
  • Page 104 Premium 2-Cycle Oil Polaris also has a TC-W3 premium oil available for use in all of our 2 cycle products. We highly recommend its use if premium gold synthetic is not used. The only oil rec- ommended for this ATV is Polaris brand oil.
  • Page 105 Kick Starter If the battery is weak and cannot start the en- gine, kick start lever will allow vehicle operation until repairs can be made. 1. Be certain your vehicle is on a level surface and the parking brake is set. See page 58. 2.

  • Page 106: Starting The Engine

    STARTING THE ENGINE Procedure for Starting a Cold Engine Indicates a potential hazard which could result in WARNING severe injury or death. Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors.
  • Page 107 1. Set the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Attach tether strap to machine and wrist. 5. Turn the engine stop switch to RUN. 6. Turn the ignition key to ON. 7.

  • Page 108: Safe Riding Gear

    RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding.
  • Page 109 RIDING GEAR 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3.

  • Page 110: Vehicle Break In Period

    VEHICLE BREAK-IN PERIOD 2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period.
  • Page 111 3. Drive slowly at first. Select an area which is open and will give you room to familiar- ize yourself with vehicle operation and handling. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.
  • Page 112 VEHICLE BREAK-IN PERIOD After the break in period the oil injection system provides the necessary engine lu- brication without the need for pre-mixed fuel. Fill the oil tank when you refuel your ATV. If you don’t serious engine damage could result. After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pump is functioning properly.

  • Page 113: Carrying Loads

    The Sportsman 90 has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
  • Page 114 CARRYING LOADS 2/3 of Load on Rear Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack.
  • Page 115 HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill. ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unse- cured loads can create unstable operating conditions, which could result in loss of control of the vehicle.
  • Page 116 CARRYING LOADS EXTREME CAUTION MUST BE USED when operating with loads ex- tending over the rack sides. Stability and maneuverability may be ad- versely affected, causing the machine to overturn. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.

  • Page 117: Daily Pre-Ride Check

    DAILY PRE-RIDE CHECK WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper check is not done, severe injury or death could result.
  • Page 118 DAILY PRE-RIDE CHECK Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3.
  • Page 119 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 inspect vehicle for any damaged or loose nuts/bolts or fas- teners 12.

  • Page 120: Riding

    RIDING...
  • Page 121 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up. 3. Check your surroundings and determine your path of travel. 4. Release the parking brake. 5.
  • Page 122 RIDING Making Turns...
  • Page 123 RIDING Practice making turns at slow speeds. Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.
  • Page 124 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or dur- ing cold freezing weather, special attention must be paid to prevent vehicle turnover.
  • Page 125 Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
  • Page 126 RIDING Traveling Uphill 15_ Maximum...
  • Page 127 Do not operate this machine on hilly terrain. If you cannot avoid operating in hilly terrain, use extreme caution. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. If you have to travel uphill always travel straight uphill and: 1.
  • Page 128 RIDING Sidehilling...
  • Page 129 Avoid traveling across the side of a hill at all costs. In the event you do enter into a situation where sidehilling is unavoidable, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests.
  • Page 130 RIDING Traveling Downhill...
  • Page 131 Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the the front and rear brakes at the same time and very slightly to aid in slow- ing.
  • Page 132 RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.
  • Page 133 1. Stop and lock the parking brake while maintaining body weight uphill. 2. Shut off engine. 3. Dismount on left or uphill side of ATV. 4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV). 5. While holding service brake, release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward.
  • Page 134 RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the foot- rests.
  • Page 135 Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the levers until braking action is normal.
  • Page 136 RIDING Trail Obstacles...
  • Page 137 Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.
  • Page 138 RIDING Parking on an Incline...
  • Page 139 RIDING Whenever the Vehicle is Parked 1. Turn the engine off. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown on the facing page. 4.

  • Page 140: Pvt System Operation

    D Routine maintenance is the responsibility of the owner. Always follow recommended 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.
  • Page 141 If the vehicle is operated in dusty areas, it will be necessary to clean the filter more often. To clean the PVT filter: 1. Remove the screws and the crankcase cover. 2. Remove the screws and the filter cover. 3. Soak the filter in a mild detergent and rinse with clean water. 4.

  • Page 142: Battery

    BATTERY Battery Only adults should ever touch the battery. Never allow children to handle a battery or service a battery in any way. Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an ex- plosive situation could result causing serious injury or death.
  • Page 143 Indicates a potential hazard which could result WARNING in severe injury or death. Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.
  • Page 144 BATTERY Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

  • Page 145: Battery Removal

    Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable next. 4. Lift the battery out of the ATV, being careful not to tip it sideways and spill electro- lyte.
  • Page 146 BATTERY Battery Installation and Connections To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death. Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush.
  • Page 147 1. Set the battery in its holder. 2. First connect and tighten the red (positive) cable. 3. Second connect and tighten the black (negative) cable. 4. Attach the hold down strap. 5. Verify that cables are properly routed. NOTE: D When your ATV is placed in storage for three months or more, the battery should be removed, charged to proper level, and stored in a cool dry place.

  • Page 148: Noise Emission Control System Regulation

    NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed...
  • Page 149 NOISE EMISSION CONTROL SYSTEM REGULATION 2. Removal or alteration or the puncturing of any part of the engine air induction system. 3. Replacement of any vehicle parts with parts not in compliance with federal regulations. 4. Lack of proper maintenance. Engine and exhaust parts can become very hot after use.
  • Page 150 NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

  • Page 151: Maintenance

    MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compart- ment under the seat. Items included in the kits are: 2-cycle engines D spark plug wrench with Phillips head screwdriver D tire pressure gauge Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition.
  • Page 152 Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and ad- justment procedures, have a qualified dealer perform these operations.
  • Page 153 " More often under severe use, such as dirty or wet conditions Item Brake System Tires Wheels Frame nuts, bolts, fasteners Oil Level Air Filter " Brake pad wear Battery Hours or When Remarks Miles Pre-ride Pre-ride Pre-ride inspection item Pre-ride Pre-ride Inspect daily, pre-ride inspection item Pre-ride...
  • Page 154 MAINTENANCE Periodic Maintenance Schedule (Cont.) Due to the nature of the adjustments marked with a it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions Item...
  • Page 155 Item Hours or Miles Throttle Cable/ 50 hrs ETC Switch Steering 50 hrs " Rear Axle 50 hrs " Front Suspension 50 hrs " Rear Suspension 50 hrs " Drive Chain 50 hrs " Clutches (drive 100 hrs and driven) When Remarks Inspect-adjust, lubricate, replace if neces-...
  • Page 156 MAINTENANCE Due to the nature of the adjustments marked with a is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions Item Engine Mounts Spark Plug Ignition Timing...
  • Page 157 Item Fuel System Fuel Filter Spark arrestor Front wheel bear- ings Idle Speed Toe adjustment Hours or When Remarks Miles Check for leaks at tank cap, lines, fuel hours months valve, filter, pump and carburetor. Re- place lines every two years. 100 hrs Replace annually months...

  • Page 158: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations Item 1. Engine Oil 2. Transmission Oil Lube Method Rec. Polaris Fill oil tank. See page 63. Injection Polaris See Page 148 Premium Synthetic gear case lube Frequency* As needed, when refuel- Change annually or at 100 hours...
  • Page 159 Lubrication Recommendations Operating Range MAINTENANCE 2. Transmission (plug)
  • Page 160 4. Front A-Arm More often under severe use, such as wet or dusty conditions. **Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 40 hours or approximately 500 miles, or after submerging in water or before long periods of storage or after pressure washing.
  • Page 161 MAINTENANCE NOTE: Hours are based on 10 mph average.
  • Page 162 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Interval Date Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs. Servicing Dealer or Person Remarks...
  • Page 163 MAINTENANCE Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person...
  • Page 164 MAINTENANCE Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, result- ing in loss of control and possible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1.
  • Page 165 2. Loosen the four bolts. 3. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right. 4. Torque handlebar adjuster block bolts to 7.3 ft. lbs. NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar block.

  • Page 166: Front Wheel Hub Tightening

    NOTE: All nuts that have a cotter pin installed must be serviced by an autho- rized Polaris Dealer. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component opera- tions. Service work must be performed by your authorized Polaris dealer.

  • Page 167: Rear Spring Adjustment

    Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction re- quired to increase or decrease spring ten- sion. MAINTENANCE Rear Spring Adjustment...

  • Page 168: Air Cleaner

    MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation. If the vehicle is ridden in wet or dusty conditions, clean the filter more often. Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine.
  • Page 169 To clean the filter: 1. Remove the screws on the airbox (A) and re- move the filter (B). 2. Soak the filter in a mild detergent and rinse it in clean water. 3. Let the filter air dry and reinstall in the air box. MAINTENANCE...
  • Page 170 MAINTENANCE Throttle Stop System The throttle stop system controls how far the throttle opens. To adjust, loos- en the jam nut (D), turn the screw (E) inward to reduce speed and outward to increase speed. Tighten the jam nut after adjusting.

  • Page 171: Exhaust System Restrictor

    MAINTENANCE Exhaust System Restrictor The exhaust restrictor system restricts exhaust gas flow, reducing the maximum power output of the engine. Exhaust System Restrictor Removal The Scrambler 50 utilizes a restrictor at the headpipe exhaust flange and at the spark arrestor. Make certain the engine and exhaust system is cool to avoid burns.

  • Page 172: Spark Arrestor Restrictor

    Torque to 10 ft. lbs. (1.0 kgf-m) Spark Arrestor Restrictor The Scrambler 90 and the Sportsman 90 utilize a restrictor at the spark arrestor only. Make certain the engine and exhaust system is cool to avoid burns.

  • Page 173: Steering Inspection

    The camber and caster are non-adjustable. Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments.

  • Page 174: Toe Alignment

    MAINTENANCE Toe Alignment You can check the toe alignment of the ve- hicle using the following method. The rec- ommended toe alignment is 1/8″ to 1/4″ (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1.
  • Page 175 Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

  • Page 176: Brake Adjustment

    140MAINTENANCE Brake Adjustment Periodically check the freeplay of the front and rear brakes. Refer to the chart below for the acceptable range of freeplay for your ma- chine. To adjust the front brake, turn the adjustment knob (A) until the freeplay is acceptable.
  • Page 177 MAINTENANCE To adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is attained.

  • Page 178: Brake Freeplay Adjustment

    MAINTENANCE Model Sportsman 90 Scrambler 90 Scrambler 50 Brake Freeplay Adjustment Front .39″ - .78″ 10 mm - 20 mm .39″ - .78″ 10 mm - 20 mm .1″ - .39 ″ 2.5mm - 9.9 mm Rear .39″ - .78″...
  • Page 179 Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept between 1/16″ and 1/8 ″ (1.5mm - 3.2mm) (C). If adjustment is required, turn the adjustment nut (D) until the freeplay falls in to the acceptable limit.

  • Page 180: Spark Plugs

    MAINTENANCE Spark Plugs The spark plug required for this machine is NGK BP7HS or NGK BPR7HS. Incorrect spark plug gap can cause the spark plugs to foul. The spark plug gap should be be- tween 0.6 - 0.7 mm. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds.
  • Page 181 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.
  • Page 182 Fuel additive products are available through your Polaris dealer. NOTE: Before storing the machine, add lubricant to the fuel in the tank at a 40:1 ratio and then run the engine for three to five minutes.
  • Page 183 Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. WARNING Indicates a potential hazard which could result in severe injury or death. MAINTENANCE...

  • Page 184: Transmission Lubrication

    With the ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lubricant to use is Polaris Pre- mium Synthetic Gearcase Lubricant (PN 2871478).
  • Page 185 2. Remove transmission drain plug and drain the oil. Catch and discard used oil prop- erly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to full mark on the fill plug/dipstick. 5. Check for leaks.
  • Page 186 MAINTENANCE Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. WARNING...
  • Page 187 Important Safeguards Maintain proper tire pressure according to chartson page 152. Improper tire inflation may affect ATV maneuverability. Do not use improper tires. The use of non-standard size or type tires may affect ATV handling. Make certain the wheels are installed properly. If wheels are improperly installed it could affect vehicle handling and tire wear.
  • Page 188 MAINTENANCE Scrambler 50 Front Rear Scrambler 90 Front Rear Sportsman 90 Front Rear Tire Size 16 x 8 - 7 16 x 8 - 7 18 x 7 - 7 18 x 9.5 - 8 19 x 7 - 8 18 x 9.5 - 8...

  • Page 189: Wheel Installation

    Wheel Installation 1. With the park brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2. Attach the wheel nuts and finger tighten them.

  • Page 190: Tire Inspection

    MAINTENANCE Tire Inspection When replacing a tire always use original equip- ment size and type. Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) (1) or less.
  • Page 191 Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. Never wash the chain with a high pressure washer or gasoline. Damage to the O-rings will result, causing premature wear and drive chain failure.
  • Page 192 MAINTENANCE Drive Chain Inspection and Adjustment (Cont.) The adjuster stud must be held secure when tightening jam nuts or the stud may break. CAUTION...
  • Page 193 Rear Drive Chain Slack Adjustment Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. The normal chain slack should be kept between .40″ - .80″...
  • Page 194 MAINTENANCE Adjustment Procedure 1. Loosen 4 rear housing mount bolts (A). 2. Tighten chain adjuster (B) to reduce slack to recommended setting. (.4″ - .8″ / 10 mm - 20 mm) 3. Tighten jam nuts on chain adjuster. 4. Tighten the four rear housing mount bolts.
  • Page 195 Brakelight Lamp Replacement If the brakelight does not work the lamp may need to be replaced. 1. From the rear of the brake light remove two screws (A) holding lens cover in place and remove lens cover (B). 2. Remove lamp (C) and replace it with recom- mended lamp.

  • Page 196: Cleaning Your Atv

    MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels.
  • Page 197 Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement.
  • Page 198 MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off. 2. Be certain the fuel cap, oil cap, and seat are installed correctly. 3. Always tie the frame of the ATV to the transporting unit securely using suitable straps or rope.
  • Page 199 Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjust- ments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation.

  • Page 200: Specifications

    SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Scrambler 50 49cc Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liter) 1.3 gallons (5 liters) Electric with kick-start backup Automatic CVT A-Arm with 2″...
  • Page 201 Front/Rear Brakes Parking Brake Front Tires / PSI Rear Tires / PSI Turning Radius Wheel Base Dry Weight Length Width Height Brake Light Low Oil Light Specifications - Scrambler 50 Drum Mechanical Lock 16 x 8-7 (2psi) 18 x 9.5 - 8 (2psi) 74.8″...
  • Page 202 SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Scrambler 90 89cc Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liter) 1.3 gallons (5 liters) Electric with kick-start backup Automatic CVT A-arm with 4.25″...
  • Page 203 Front/Rear Brakes Parking Brake Front and Rear Tires / PSI Turning Radius Wheel Base Dry Weight Length Width Height Brake Light Low Oil Light Specifications - Scrambler 90 Drum Mechanical Lock 18 x 7 - 7 (2psi) 98.4″ (250 cm) 35.4″...
  • Page 204 Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Sportsman 90 89cc Fan Cooled 2-Stroke Oil Injected 1.1 qts. (1 ltr) 1.3 ga. (5 ltr) Electric with kick-start backup Automatic CVT A-arm with 4.25 in / 10.8 cm of travel Spring over shock with 4.25 in / 10.8 cm of...
  • Page 205 Wheel Base Turning Radius Dry Weight Length Width Height Brake Light Specifications - Sportsman 90 Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 37.8″ (96 cm) 98.4″ (250 cm) 238.1 lbs (108 kgs) 57.6″...
  • Page 206 Low Oil Light Front Rack Capacity Rear Rack Capacity Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polar- is dealer to find out about the accessories available for your machine. Specifications - Sportsman 90 Standard 10 lb (4.5 kgs)

  • Page 207: Wiring Diagrams

    WIRING DIAGRAM...
  • Page 208 WIRING DIAGRAM...

  • Page 209: Trouble Shooting

    Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START...
  • Page 210 TROUBLESHOOTING No Fuel Turn Fuel Valve to “Res” Fuel Vent Line Kinked or Plugged Water in Fuel ENGINE STOPS OR LOSES POWER Spark Plug Fouled Air Filter Clogged Electronic Throttle Control Malfunction Contact Your Dealer Engine Overheated Clean Engine Exterior Contact Your Dealer...

  • Page 211: Warranty

    LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited war- ranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty.
  • Page 212 At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV.
  • Page 213 WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any...
  • Page 214 ATV. The exclusive remedy for breach of this warran- ty shall be, at Polaris’ exclusive option, repair or replacement of any defective materi- als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 215 HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
  • Page 216 Please work with your dealer to resolve any warranty issues. Should your dealer re- quire any additional assistance they will contact the appropriate person at Polaris. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

  • Page 217: Table Of Contents

    Air Cleaner ....Battery Installation ... . . Battery Maintenance ... Battery Removal .

  • Page 218: Table Of Contents

    INDEX Maintenance Schedule ..Making Turns ....Noise Control System ..Oil System ....Oil System .
  • Page 219 Warranty ....Wheel Installation ..Wheel Nut Torque ... . . 175-180 Wheel Removal 151-153...
  • Page 220 Always use an approved helmet and protective gear 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 - passen- gers affect balance and steering and increaqse risk of losing control.

This manual is also suitable for:

Scrambler 50Scrambler 90

Table of Contents