Polaris OUTLAW 90 Owner's Manual
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Polaris OUTLAW 90 Owner's Manual

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Owner's Manual for Maintenance and Safety
OUTLAW 90
SPORTSMAN 90
Read this manual carefully. It contains important safety information.
Adult supervision is required at all times.
Operation is prohibited for anyone under age 10.

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Summary of Contents for Polaris OUTLAW 90

  • Page 1 Owner's Manual for Maintenance and Safety OUTLAW 90 SPORTSMAN 90 Read this manual carefully. It contains important safety information. Adult supervision is required at all times. Operation is prohibited for anyone under age 10.
  • Page 2 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.
  • Page 3 - pavement may GEAR seriously affect handling and control READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 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.
  • Page 4 Visit us at www.polarisindustries.com...
  • Page 5 POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are registered trademarks of POLARIS Industries Inc. Copyright 2012 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 produc- tion components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 6 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.
  • Page 7 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.

  • Page 8: Table Of Contents

    Maintenance ... . . 98 Specifications... . 162 POLARIS Products ..167 Troubleshooting ..168 Warranty .

  • Page 9: Introduction

    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. CAUTION A CAUTION indicates a hazardous situation The safety alert symbol indicates a potential which, if not avoided, could result in minor or...
  • Page 10 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.

  • Page 11: Safety

    ATV to take a training course. child on a regular basis. Do not allow other If you purchased a new POLARIS ATV in children to ride this ATV unless they have the United States, your dealer provided...

  • Page 12: Safety Training

    Safety Safety Training If you purchased a used POLARIS ATV in FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the the United States, you can enroll in the ATV Consumer Product Safety Commission RiderCourse for a fee. Call ATV at 1-800-638-2772, or visit www.cpsc.gov,...

  • Page 13: Riding Gear

    Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a Protection Gloves helmet that meets or exceeds established safety stan- dards.
  • Page 14 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.

  • Page 15: Equipment Modifications

    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.

  • Page 16: Safety Warnings

    Safety Safety Warnings WARNING 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.
  • Page 17 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.
  • Page 18 Safety Safety Warnings Handling Gasoline Exposure to Exhaust Gasoline is highly flammable and explosive Engine exhaust fumes are poisonous and can under certain conditions. cause loss of consciousness or death in a short time. Never start the engine or let it run in an •...
  • Page 19 Safety Safety Warnings Failure to Inspect Before Operating Protective Apparel Failure to inspect and verify that the ATV is in Operating this ATV safe operating condition before operating without wearing an increases the risk of an accident. Always inspect approved helmet the ATV before each use to make sure it's in safe increases the risk of operating condition.
  • Page 20 Safety Safety Warnings Carrying a Passenger Using Alcohol or Drugs Carrying a passenger greatly reduces the Operating the ATV after consuming alcohol or operator's ability to balance and control the ATV, drugs could adversely affect operator judgment, which may result in an accident or overturn. reaction time, balance and perception.
  • Page 21 Safety Safety Warnings Operating on Pavement Operating on Public Roads Operating an ATV on paved surfaces (including Operating this ATV on public streets, roads or sidewalks, paths, parking lots and driveways) highways could result in a collision with another may adversely affect the handling of the ATV and vehicle.
  • Page 22 Safety Safety Warnings Operating at Excessive Speeds Physical Control of the ATV Operating the ATV at excessive speeds Removing a hand from the handlebars or feet increases the operator's risk of losing control. from the footrests during operation can reduce Always operate at a speed that's appropriate for your ability to control the vehicle or cause loss of the terrain, the visibility and operating conditions,...
  • Page 23 Safety Safety Warnings Turning Improperly Jumps and Stunts Turning improperly could cause loss of traction, Attempting wheelies, jumps and other stunts loss of control, accident or overturn. Always increases the risk of an accident or overturn. follow proper procedures for turning as described Never attempt wheelies, jumps, or other stunts.
  • Page 24 Safety Safety Warnings Improper Hill Climbing Operating on Steep Hills Improper hill climbing could cause loss of control Operating on excessively steep hills could cause or overturn. Always follow proper procedures for an overturn. Never operate on hills too steep for climbing hills as described in the owner's the ATV or for your abilities.
  • Page 25 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. •...
  • Page 26 Safety 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.
  • Page 27 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).
  • Page 28 Safety 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.
  • Page 29 Safety Safety Warnings Operating in Unfamiliar Terrain Improper Tire Maintenance Failure to use extra caution when operating on Operating this ATV with improper tires or with unfamiliar terrain could result in an accident or improper or uneven tire pressure could cause overturn.
  • Page 30 POLARIS Industries Inc. or equivalent Skidding or Sliding components designed for use on this ATV and Skidding or sliding can cause loss of control or should be installed and used according to overturn (if tires regain traction unexpectedly).
  • Page 31 Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the footrests: •...
  • Page 32 Safety Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo may cause changes in handling, which could cause loss of control or an accident. Never haul cargo or tow a load with this ATV. Never tow or pull an object behind the ATV. A wagon, sled or other towed object does not have brakes or steering.
  • Page 33 Safety Safety Warnings Operating on Frozen Bodies of Water Physical Skills Operating on frozen bodies of water may result in Safe operation of this rider-active vehicle serious injury or death if the ATV and/or the requires good judgement and physical skills. operator fall through the ice.
  • Page 34 Safety European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
  • Page 35 If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
  • Page 36 Safety Safety Labels and Locations Operation Warning WARNING Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear. Never use on public roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: without proper training or instruction;...
  • Page 37 Safety Safety Labels and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 15 degrees 15°. To prevent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill. REVERSE operation can be dangerous even at low speeds.
  • Page 38 Safety Safety Labels and Locations Tire Pressure Warning (OUTLAW 90) WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa) •...
  • Page 39 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
  • Page 40 Safety Safety Labels and Locations SPORTSMAN 90 Rack Warning WARNING • DO NOT TOW. Vehicle damage or tipover may result causing severe injury or death. • Maximum Rack Loads: Front 15 lbs. (7 kg) Rear 30 lbs. (14 kg)
  • Page 41 Safety Safety Labels and Locations Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To pre- vent serious injury, do not operate vehicle with guard removed. • Do not touch clutch cover, cover may become hot. •...

  • Page 42: Youth Section

    Youth Section...

  • Page 43: Know Your Atv

    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 126.
  • Page 44 Know Your ATV Before you have an adult start the engine for you for the first time, let's learn about the con- trols on your new ATV. 1. Engine Stop Switch - When the engine is running, push this button down to shut the engine off quickly.
  • Page 45 Know Your ATV 4. Kick-Start Lever - If your battery is too weak to start your ATV, you can 5. Shift Lever 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 68.
  • Page 46 Know Your ATV 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. 6. Gas Cap Always have an adult put gas in your ATV.
  • Page 47 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.
  • Page 48 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.
  • Page 49 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.

  • Page 50: Pre-Ride Check

    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.
  • Page 51 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.
  • Page 52 Pre-Ride Check 4. If you used the storage area under the seat, make sure the seat is locked in place. 5. 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.

  • Page 53: Riding Rules

    Riding Rules Now you're ready to learn about riding your POLARIS ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driv- ing an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.
  • Page 54 Riding Rules Always wear the right kind of clothing and safety gear when riding your ATV. Long Helmet Helmet: Your helmet is very important for safe riding. A Sleeves helmet can prevent a severe head injury. Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you can see where you're driving.
  • Page 55 Riding Rules Always attach the tether strap to your right wrist and to the ATV before riding. Make sure you know where you're going to drive before your ATV is started. Make sure the area is safe all around your ATV. Your ATV is made for one person.
  • Page 56 Riding Rules Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. Never ride on public trails. 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.
  • Page 57 Respect your ATV; respect your environment; and you will earn the respect of everyone. Enjoy riding your new POLARIS ATV!

  • Page 58: Adult Section

    Adult Section...

  • Page 59: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys.

  • Page 60: Features And Controls

    Features and Controls Main Key Switch Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. Always remove the ignition key when the vehicle is not in use. OUTLAW SPORTSMAN...

  • Page 61: Choke Lever

    Features and Controls Engine Stop Switch Horn Stop Switch The engine will not start or run when the stop switch is down, in the OFF position. Its pur- pose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency.

  • Page 62: Horn Button

    Features and Controls Horn Button Use the horn for emergencies and to let others know you’re near. Engine Start Button The start button is located slightly above the choke lever. Follow the Starting the Engine procedure beginning on page 76.
  • Page 63 Features and Controls Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

  • Page 64: Throttle Lever

    Features and Controls Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. Engine speed returns to idle when the lever is released. This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle.

  • Page 65: Shift Lever

    Features and Controls Shift Lever To change gears, stop the ATV. With the engine idling, move the lever to the desired gear. Do not try to shift gears with engine speed above idle or while the ATV is moving. Shift Lever Maintaining shift linkage adjustment is important to assure proper transmission function.
  • Page 66 Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes. WARNING! Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time.
  • Page 67 Features and Controls Brakes Parking Brake Not Locked 1. Squeeze the left brake lever. Locked 2. Push the parking brake lock down to lock the brake lever in place. 3. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever.
  • Page 68 Lights WARNING POLARIS Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visibility. This ATV is designed for off-road use only. Do not operate this ATV on streets or highways.

  • Page 69: Fuel System

    Use POLARIS Carbon Clean fuel treatment at each fill. Follow the mixing directions on the container. See page 168 for the part numbers of POLARIS products. Use unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Non- ethanol fuel is recommended.

  • Page 70: Fuel Valve

    ON: For normal operation. RES: For reserve supply if main supply is exhausted. The reserve setting allows operation for OUTLAW 90 approximately 7-10 miles (11-16 km). Fuel Valve Always refill the gas tank as soon as possible after using the main supply.
  • Page 71 Features and Controls Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3.

  • Page 72: Operation

    Break-in Period The break-in period for your new POLARIS 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in.
  • Page 73 Operation Break-in Period 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. See page 15. 2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the proper range. See page 109. 3.
  • Page 74 Operation Break-in Period 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 72. 6. Perform the following maintenance at the end of the break-in period. Item End of Break-In Remarks Page Engine oil change Perform break-in oil change...
  • Page 75 Operation Pre-Ride Inspection 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. Pre-Ride Checklist Item Remarks Page...
  • Page 76 Operation Pre-Ride Inspection Pre-Ride Checklist Item Remarks Page Throttle Check for proper operation 47, 60, 61 Engine stop switch Check for proper function Daytime running lights (if equipped) Check for proper operation Brakelight Check for proper operation Air filter, pre-filter Inspect, clean or replace Drive chain Check condition and slack;...

  • Page 77: Safe Operation Practices

    Operation Safe Operation Practices 1. Complete the recommended safety 5. Operate this vehicle off-road only. training before operating this vehicle. Never operate the vehicle on pavement See page 8. or on any public street, road or highway, including dirt and gravel roads. 2.
  • Page 78 Operation Safe Operation Practices 7. Drive in a manner appropriate for your 10. Never operate a damaged ATV. After skills and operating conditions. Never any overturn or accident, have a quali- operate at excessive speeds. Never fied service dealer inspect the entire attempt wheelies, jumps, or other stunts.

  • Page 79: Starting The Engine

    Operation Starting the Engine NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Shift the transmission to neutral. 2. Lock the parking brake. 3. Turn the fuel valve on. 4.
  • Page 80 Operation Starting the Engine 7. Turn the ignition key to ON. 8. Squeeze the rear brake lever and press the starter button. The rear brake lever must be engaged or the engine won't start. 9. Do not press the throttle while starting the engine. Activate the starter for a maximum of five seconds, releasing the button when the engine starts.

  • Page 81: Stopping The Engine

    Operation Stopping the Engine 1. Release the throttle completely. 2. Apply the brakes until the vehicle stops moving. 3. Shift the transmission to neutral. 4. Stop the engine. There are three ways to stop the engine: • Turn the key off. •...

  • Page 82: Driving Procedure

    Operation Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Shift the transmission to neutral. 3. Start the engine and allow it to warm up. 4. Check your surroundings and determine your path of travel.

  • Page 83: Making Turns

    Operation Making Turns Your ATV is 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 84: Driving In Reverse

    Operation Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6.

  • Page 85: Driving On Slippery Surfaces

    Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas.
  • Page 86 Operation Driving on Slippery Surfaces 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
  • Page 87 Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (15° maximum). 3.

  • Page 88: Driving Uphill

    Operation Driving Uphill 5. Keep both feet on the footrests. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards. 8. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
  • Page 89 Operation Driving on a Sidehill (Sidehilling) 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 sidehill is unavoidable, follow these precautions: 1.

  • Page 90: Driving Downhill

    Operation Driving Downhill When driving downhill, follow these precau- tions: 1. Avoid steep hills (15° maximum). 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when trav- eling downhill can cause loss of control.

  • Page 91: Turning Around On A Hill

    Operation Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2.
  • Page 92 Operation Turning Around on a Hill 7. Lock the parking brake and remount the ATV from the uphill side, keeping body weight uphill. 8. Restart the engine. 9. Squeeze the rear brake lever. 10. Shift the transmission to forward gear. 8 ft.
  • Page 93 Operation Parking on a Hill or Incline Avoid parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Lock the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illus- tration.

  • Page 94: Driving Over Obstacles

    Operation Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operat- ing in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3.
  • Page 95 Operation Driving Through Water Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests. Follow these precautions when operating through water: 1. Determine water depth and current before entering water.

  • Page 96: Driving Through Water

    Operation Driving Through Water 4. After driving through water, dry the brakes by applying light pressure to the levers (while moving) until braking action is normal. If you do not perform this procedure, your brakes may be ineffective. NOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footrest level.

  • Page 97: Hauling Cargo

    Operation Hauling Cargo The SPORTSMAN 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling cargo on the following pages. Never carry cargo on the OUT- LAW 90. WARNING Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control, which can result in serious injury or death.
  • Page 98 Operation Hauling Cargo • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section beginning on page 162. • Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or a tipover.

  • Page 99: Emission Control Systems

    Operation on Public Lands in the U.S.A. Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS stan- dard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

  • Page 100: Exhaust Emission Control System

    Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at POLARIS specifications to achieve opti- mal performance. Engine idle speed is the only adjustment POLARIS recommends that the operator perform. Any other adjust- ments should be performed by an authorized POLARIS dealer.

  • Page 101: Maintenance

    Maintenance Periodic Maintenance Chart To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

  • Page 102: Periodic Maintenance Chart

    Periodic Maintenance Chart Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 103 Emission-related service (failure to conduct this maintenance will not void the emissions war- ranty but may affect emissions) Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and cause an accident, which may result in serious injury or death.
  • Page 104 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Page Hours Calendar Miles (Km) Steering Daily Check each day before operating the vehicle. Make adjustments as Front suspension Daily needed. See the Pre-Ride Check- Rear suspension Daily list. Tires Daily Brake lever travel...
  • Page 105 100 (160) Check; adjust as needed Choke Monthly 100 (160) Check for proper operation; see your dealer for adjustments Perform these procedures more often for vehicles subjected to severe use. Emission-Related Service Have an authorized POLARIS dealer perform these services.
  • Page 106 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Page Hours Calendar Miles (Km) Battery Monthly 200 (320) Check terminals; clean; test Engine oil change 300 (480) Drain and change the oil Transmission oil 12 M 400 (640) Drain and change the oil Oil pre-filter screen 12 M...
  • Page 107 12 M 1000 (1600) Inspect Exhaust muffler/pipe 12 M 1000 (1600) Inspect Ignition timing 12 M 1000 (1600) Inspect Perform these procedures more often for vehicles subjected to severe use. Emission-Related Service Have an authorized POLARIS dealer perform these services.
  • Page 108 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Page Hours Calendar Miles (Km) Wiring 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connec- tors subjected to water, mud, etc. Clutches (drive and driven) 12 M 1000 (1600) Inspect;...

  • Page 109: Lubrication Guide

    Extreme Duty 4-Cycle Oil Gearcase (Transmis- Premium AGL Synthetic See page 114. sion) Oil Level Gearcase Lube Drive Chain POLARIS Chain Lube or SAE See page 137. 80/90 Front Suspension POLARIS All Season Premium Inspect; tighten fasteners; (A-Arm) Grease or grease conforming to grease (also after washing NLGI No.
  • Page 110 Maintenance Lubrication Guide Grease Points Grease Points...

  • Page 111: Engine Oil

    Chart beginning on page 98. POLARIS recommends the use of POLARIS PS-4 Extreme Duty 4-Cycle engine oil for this vehicle. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. See page 168 for the part numbers of POLARIS products.

  • Page 112: Engine Oil Check

    Maintenance Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4.

  • Page 113: Engine Oil Change

    Maintenance Engine Oil Change 1. Position the vehicle on a level surface. 2. Clean the area around the pre-filter plug. 3. Start the engine. Allow it to idle for two to three minutes. 4. Stop the engine. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
  • Page 114 Maintenance Engine Oil Change 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry. 8.
  • Page 115 Maintenance Engine Oil Change 10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm). 11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. See the specifications section beginning on page 162 for capacities. 12.

  • Page 116: Fuel Filter

    Maintenance Fuel Filter The POLARIS ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. Do not attempt to clean the fuel filter.

  • Page 117: Transmission Oil Check

    Periodic Maintenance Chart beginning on page 98. POLARIS recommends the use of AGL Synthetic Gearcase Lubricant. Fill Plug See page 168 for the part numbers of POLARIS products. Drain Plug 1. Position the vehicle on a level surface.

  • Page 118: Gearcase Capacity

    6. Add the recommended oil. Maintain the oil level at the bottom of the fill plug hole threads. 7. Reinstall the fill plug. Check for leaks. 8. Dispose of used oil properly. Gearcase Capacity OUTLAW 90 11.8 oz. (350 ml) SPORTSMAN 90 11.8 oz. (350 ml)

  • Page 119: Spark Plugs

    NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds.
  • Page 120 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white. A white insulator tip indicates overheat- ing, caused by use of an improper spark plug or incorrect fuel system operation.

  • Page 121: Vehicle Immersion

    Maintenance Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service, or after 25 hours. Vehicle Immersion If the vehicle tips or overturns in water deeper than the footrest level, or if the engine stops during or after operating in water, restarting WILL result in serious engine damage.
  • Page 122 Maintenance Vehicle Immersion 5. Loosen the carburetor drain screw. 6. Turn the engine over several times using the electric start. 7. Dry the spark plug and reinstall it, or replace it with a new plug. 8. Tighten the carburetor drain screw. 9.
  • Page 123 • Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. • This CVT system is intended for use on POLARIS products only. Do not install it in any other prod- uct. • Always make sure the CVT housing is securely in place during operation.

  • Page 124: Cvt Drying

    Maintenance CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is located on the bot- tom of the CVT cover. 1.

  • Page 125: Spark Arrester

    Maintenance Spark Arrester To remove accumulated carbon, clean the spark arrester at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. WARNING Failure to heed these warnings could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Allow components to cool suffi- ciently before proceeding.
  • Page 126 Maintenance Spark Arrester 1. Remove the six bolts and remove the arrester from the end of the muffler. 2. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with com- pressed air.
  • Page 127 8,000 feet (2400 m) and temperatures above 15° F (-9° C). Refer to the specifi- cations section beginning on page 162 for carburetor and jetting specifications. Any jetting changes must be made only by an authorized POLARIS dealer. Always see your dealer if jetting changes are needed.
  • Page 128 Maintenance Carburetor If engine idle speed is too high the vehicle will creep. If idle speed is too low the engine will stall. To adjust idle speed, do the following: 1. Lock the parking brake. 2. Start the engine. 3. Allow the engine to warm up for approximately five minutes. 4.

  • Page 129: Speed Control System

    The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer's request, remove or adjust any speed limiting devices. Your POLARIS ATV has an adjustable throttle limiting screw. Speed limiting devices may be adjusted/removed only by consumers when they determine that their child is capable of handling the additional speed.
  • Page 130 Maintenance Speed Control System Throttle Stop Speed Control System Use the following procedure to control how far Jam Nut the throttle opens. Screw 1. Loosen the jam nut. 2. Turn the screw inward to reduce speed or outward to increase speed. 3.

  • Page 131: Throttle Cable Adjustment

    Maintenance 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" (1.5 - 3.2 mm). If adjustment is required, turn the adjustment nut until the freeplay falls in to the acceptable limit.

  • Page 132: Brake Freeplay

    Maintenance Brake Freeplay Measure Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals rec- ommended in the Periodic Maintenance Chart beginning on page 98. If the free- play isn’t at specification, adjust the freeplay as outlined on the following pages.
  • Page 133 Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground.
  • Page 134 Maintenance Brake Freeplay Front Brake Adjustment 6. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 7. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn.
  • Page 135 Maintenance Brake Freeplay Rear Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the rear of the vehicle by placing a suitable stand under the frame. The rear tires should be slightly off the ground.

  • Page 136: Brake Lever Travel

    Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. When freeplay specifications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine when to service the brakes.

  • Page 137: Toe Alignment

    Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position.
  • Page 138 1/8" to 1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service.

  • Page 139: Steering Inspection

    Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension.

  • Page 140: Drive Chain

    Maintenance Drive Chain Lubricate the drive chain with POLARIS chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 98. Lubricate more often under severe use, such as in dirty or wet conditions. See page 168 for the part numbers of POLARIS products.

  • Page 141: Drive Chain Slack

    Maintenance Drive Chain Slack 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. Collapse the suspension with an adjustable (buckle type) trailer tie- down strap. Fasten the strap around the axle and rear bumper tube.

  • Page 142: Drive Chain Slack Adjustment

    Maintenance Drive Chain Slack Adjustment 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. Turn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm).

  • Page 143: Air Filter

    Maintenance Air Filter 1. Remove the seat. See page 43. 2. Release the air box cover spring clips and remove the cover. 3. Remove the foam air filter. Wash the foam filter in warm soapy water, then rinse and let dry.
  • Page 144 Maintenance Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter and air box cover. Secure the clips. 7. Reinstall the seat. NOTICE: Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear and severe damage to the engine.

  • Page 145: Handlebar Adjustment

    Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.
  • Page 146 Maintenance Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

  • Page 147: Wheel Removal

    Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 1/8" (3 mm) Wheel Removal 1. Stop the engine and lock the parking brake. Wheel 2. Loosen the wheel bolts slightly. Bolts 3.

  • Page 148: Wheel Installation

    Maintenance Wheel Installation 1. Lock the parking brake. 2. 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. 3. Install the wheel bolts and finger tighten them. 4.

  • Page 149: Axle And Wheel Nuts

    Maintenance Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized POLARIS dealer. Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized POLARIS dealer.
  • Page 150 Maintenance Tail Light Lamp Replacement Lamp If the brakelight doesn't work, the lamp may need to be replaced. Cover 1. Remove the two screws securing the lens cover. Remove the lens cover. 2. Remove the lamp and replace it with a Screws new recommended lamp.
  • Page 151 Maintenance Indicator Light Lamp Replacement 1. Remove the handlebar cover or pod to access the lamps. 2. Remove the indicator wire connections from the harness. 3. Remove the nut from the back side of the indicator lamp. 4. Remove the lamp. 5.
  • Page 152 Maintenance Daytime Running Lights Lamp Replacement (if equipped) If the daytime running lights do not operate, replace the lamps. POLARIS recommends that you install replacement lamps obtained from your authorized POLARIS dealer. 1. Remove the front cab (OUTLAW only). 2. Disconnect the lights from the harness.
  • Page 153 When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. The battery in your POLARIS ATV is a sealed battery. The sealing strip cannot be removed. Never add water to this type of battery.
  • Page 154 Maintenance Battery Battery Removal 1. Disconnect the hold-down straps securing 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.
  • Page 155 Maintenance Battery Battery Installation and Connections Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger 1.
  • Page 156 Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.
  • Page 157 Cleaning Washing the ATV The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.
  • Page 158 • Cab and body panels • Transmission seals • Labels and decals If warning and safety labels are damaged, contact your POLARIS dealer for free replace- ment. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to...
  • Page 159 Maintenance Polishing POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehi- cle.
  • Page 160 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 153. Battery Storage Remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
  • Page 161 Storage Stabilize the Fuel POLARIS Carbon Clean is a fuel stabilizer and fuel system dryer. It cleans the fuel system, the combustion chamber and the exhaust ports. It also prevents bacterial growth and pro- motes better starting after the storage period.
  • Page 162 Maintenance Storage Engine Oil Change the oil. See page 110. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sedi- ment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 98.
  • Page 163 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 98. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground.

  • Page 164: Transporting The Atv

    Maintenance Transporting the ATV 1. Stop the engine. Place the transmission in gear. Lock the parking brake. 2. Secure the fuel cap, oil cap and seat. Turn the fuel valve off. NOTICE: Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting.

  • Page 165: Specifications

    Specifications OUTLAW 90 Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication Wet Sump Oil Capacity 30 oz. (900 ml) Fuel Capacity 1.7 gallons (6.4 liters) Fuel Reserve Capacity .23 gallons (.86 liters)
  • Page 166 Specifications OUTLAW 90 Dry Weight 270 lbs. (122.4 kg) Length/Width/Height 61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm) Wheel Base 41.5" (105 cm) Ground Clearance 4" (10 cm) at swing arm, 7.7" (19.5 cm) at frame Brake Light...
  • Page 167 Specifications OUTLAW 90 Carburetor Jetting *Shaded cells indicate factory settings. AMBIENT TEMPERATURE ALTITUDE °F: Below -25 -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above +60 Meters (Feet) °C: Below-35...
  • Page 168 Specifications SPORTSMAN 90 Rider Capacity/Maximum Weight 1 Rider/180 lbs. (81.7 kg) Displacement 89cc Cooling Air Cooled Engine type 4-Stroke Lubrication Wet Sump Oil Capacity 30 oz. (900 ml) Fuel Capacity 2 gallons (7.7 liters) Fuel Reserve Capacity .22 gallons (.85 liters) Starting Electric with kick-start backup Drive System...
  • Page 169 Specifications SPORTSMAN 90 Front Tires 19 x 7 - 8 (3 psi/20.7 kPa) Rear Tires 18 x 9.5 - 8 (3 psi/20.7 kPa) Dry Weight 289 lbs. (131 kg) Length/Width/Height 61.75" (157 cm) / 36.75" (93 cm) / 38.5" (98 cm) Wheel Base 41.5"...
  • Page 170 Specifications Carburetor Jetting *Shaded cells indicate factory settings. AMBIENT TEMPERATURE ALTITUDE °F: Below -25 -30 to -10 -15 to +5 0 to +20 +15 to +35 +30 to +50 +45 to +65 Above +60 Meters (Feet) °C: Below-35 -34 to -23 -26 to -15 -18 to -7 -9 to +2...

  • Page 171: Polaris Products

    POLARIS Products Part Number Description Engine Lubricant 2878920 Performance Synthetic (PS-4) Extreme Duty 4-Cycle Oil (qt./.95 l) 2878922 Performance Synthetic (PS-4) Extreme Duty 4-Cycle Oil (2 qt./1.9 l) 2878919 Performance Synthetic (PS-4) Extreme Duty 4-Cycle Oil (gal./3.8 l) 2870791 Fogging Oil, Aerosol...
  • Page 172 POLARIS Products Part Number Description Grease 2871322 All Season Premium Grease (3 oz./89 ml) 2871423 All Season Premium Grease (14 oz./414 ml) Miscellaneous Additives 2871326 Carbon Clean Plus...

  • Page 173: Troubleshooting

    Troubleshooting See your POLARIS dealer if you're unable to identify solutions using the following charts. Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Turn the fuel valve to reserve, refuel Clogged fuel valve or filter Inspect and clean or replace...
  • Page 174 Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs...
  • Page 175 Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your POLARIS dealer Incorrect ignition timing See your POLARIS dealer Mechanical failure See your POLARIS dealer...
  • Page 176 Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten...
  • Page 177 Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clean and/or replace spark plugs...
  • Page 178 Inspect, clean and/or replace spark plugs Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your POLARIS dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections...

  • Page 179: Warranty

    POLARIS All Terrain Vehicle (ATV) against defects in material or workmanship. POLARIS also gives a one year limited warranty 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 180 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 war-...
  • Page 181 Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contami- nation for which they were not designed or not intended, including but not limited to the following items: •...
  • Page 182 Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim: •...
  • Page 183 Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; failure due to snow, water, dirt or other for- eign substance ingestion/contamination;...
  • Page 184 This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR- RANTY.
  • Page 185 ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an...
  • Page 186 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.
  • Page 187 In the country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are travel- ing within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested...
  • Page 188 You may also be required to obtain documentation from POLARIS Industries in order to reg- ister your vehicle in your new country. You should warranty register your vehicle at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive...
  • Page 189 If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen outside of the country in which the vehicle was origi- nally purchased, all warranty coverage will be denied. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety informa- tion and notices regarding your vehicle.
  • Page 190 POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission reg- ulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.
  • Page 191 Warranty U.S.A. EPA Emissions Limited Warranty For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Ignition system • Fuel system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: •...
  • Page 192 Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIM- ITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.
  • Page 193 POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effec- tiveness of the vehicle's emission controls.

  • Page 194: Maintenance Log

    Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL 10 Hours (Break-in)
  • Page 195 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL 100 Hours 120 Hours 150 Hours...
  • Page 196 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL...
  • Page 197 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED / COMMENTS INTERVAL...

  • Page 198: Index

    Carburetor ....124-125 Carburetor Jetting OUTLAW 90 ... . 164 SPORTSMAN 90 ..167...
  • Page 199 Periodic Maintenance Chart . 98-105 ..Excessive Speeds Polaris Products ..168-169 Lamp Replacement ..Exposure to Exhaust Polishing .
  • Page 200 Throttle Stop Speed Control ..127 ..Operating on Steep Hills OUTLAW 90 ..162-164 Tire Tread Depth ... . . 144 . . .

This manual is also suitable for:

Sportsman 902013 outlaw 902013 sportsman 90

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