Polaris Sportsman 90 Manuals

Manuals and User Guides for Polaris Sportsman 90. We have 4 Polaris Sportsman 90 manuals available for free PDF download: Safety And Maintenance Manual, Owner's Manual, Service Manual

Polaris Sportsman 90 Safety And Maintenance Manual (221 pages)

2002 Youth ATV Models

Brand: Polaris | Category: Offroad Vehicle | Size: 1.49 MB

Safety Message to Parents
8
Additional Important Information
13
Table of Contents
15
Rider's Section
17
- Know Your Machine
  18
- Controls Overview
  20
- Engine Stop Switch
  20
- Throttle Control
  20
- Kick Starter
  21
- Gas Cap
  22
- Brake Lever
  23
- Ignition Switch
  24
- Tether Strap/ Switch
  25
- Three Ways to Stop Your ATV
  26
- Pre-Ride Check
  28
- Riding Rules
  32
Understanding Warnings
37
Safety Alert
38
General Safety and Description of Labels
41
Daily Pre-Ride Inspection
56
Daily Pre-Ride Check
56
Failure to Follow the Age Recommendations
58
Operation Warnings
58
Vehicle Identification Numbers
83
Vehicle Identification Numbers
84
Control and Parts Functions
85
- Engine Electrical Switches
  85
  - Emergency Engine Stop Switch
    86
  - Engine Start Button
    87
  - Engine Throttle
    89
- Throttle Lever
  90
- Indicator Lights
  92
  - Switches
    92
  - Front and Rear Brakes
    93
  - Parking Brake
    94
  - Warning on Gasoline
    96
  - PVT System
    98
  - Engine Fuel and Oil System
    99
- Fuel System
  99
  - The Fuel Valve
    100
  - Engine Fuel Safety/Fuel/Filter
    101
- Oil System
  102
- The Oil Tank
  102
- Polaris 2-Cycle Lubricants
  103
- Premium 2-Cycle Oil
  104
- Kick Starter Usage
  105
- Control and Parts Functions
  105
- Procedure for Starting a Cold Engine
  106
Starting the Engine
106
- Starting the Engine
  107
- Safe Riding Gear
  108
- Helmet
  108
- Clothing
  109
- Riding Gear
  109
- Boots
  109
- Gloves
  109
- Eye Protection
  109
- 2-Cycle Engines
  110
Vehicle Break in Period
110
Vehicle Break in Period
112
Carrying Loads
113
- Carrying Loads: Important Safeguards
  114
- Carrying Loads
  116
Daily Pre-Ride Check
117
Daily Pre-Ride Check
119
Riding
120
- Making Turns
  122
- Riding on Slippery Surfaces
  124
- Traveling Uphill
  126
- Sidehilling
  128
- Traveling Downhill
  130
- Turning Around on a Hill
  132
- Crossing Streams
  134
- Trail Obstacles
  136
- Parking on an Incline
  138
- Riding
  139
PVT System Operation
140
Battery
142
- Replenishing the Battery Fluid
  144
- Battery Removal
  145
- Battery Installation and Connections
  146
- Battery
  147
Noise Emission Control System Regulation
148
Tool Kits
151
Maintenance
151
- Periodic Maintenance Record
  162
- Handlebar Adjustment
  164
- Axle and Wheel Nut Torque Specifications
  166
- Front Wheel Hub Tightening
  166
- Rear Spring Adjustment
  167
- Air Cleaner
  168
  - To Clean the Filter
    169
  - Throttle Stop System
    170
- Exhaust System Restrictor
  171
- Exhaust System Restrictor Removal
  171
- Spark Arrestor Restrictor
  172
- Camber and Caster
  173
- Steering Inspection
  173
- Toe Alignment
  174
- Brake Adjustment
  176
- Brake Freeplay Adjustment
  178
- Throttle Cable Adjustment
  179
- Spark Plugs
  180
- Transmission Lubrication
  184
  - Transmission Oil Changing Procedure
    185
  - Wheel Removal Procedure
    187
  - Wheel Installation
    189
- Tire Inspection
  190
  - Tire Tread Depth
    190
  - Drive Chain Inspection and Adjustment
    191
  - Rear Drive Chain Slack Adjustment
    193
  - Brakelight Lamp Replacement
    195
- Cleaning Your ATV
  196
  - Washing
    196
  - Waxing
    197
  - Transporting
    198
- Carburetor Adjustments
  199
Maintenance
199
Specifications
200
- Specifications
  206
- Wiring Diagram
  207
- Wiring Diagrams
  208
- Engine Cranks but Fails to Start
  209
Troubleshooting
209
Engine Stops or Loses Power
210
Warranty
211
Index
217

Polaris Sportsman 90 Owner's Manual (200 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 1.56 MB

Table of Contents
8
Introduction
9
Safety Words and Symbols
9
Safety
11
- Safety Training
  12
- Riding Gear
  13
- Equipment Modifications
  15
- Safety Warnings
  16
Youth Section
42
- Know Your ATV
  43
- Pre-Ride Check
  50
- Riding Rules
  53
Adult Section
58
- Vehicle Identification Numbers
  59
- Features and Controls
  60
  - Main Key Switch
    60
  - Choke Lever
    61
  - Engine Stop Switch
    61
  - Horn Button
    62
  - Engine Start Button
    62
  - Throttle Lever
    64
  - Shift Lever
    65
  - Fuel System
    69
  - Fuel Valve
    70
- Operation
  72
  - Safe Operation Practices
    77
  - Starting the Engine
    79
  - Stopping the Engine
    81
  - Driving Procedure
    82
  - Making Turns
    83
  - Driving in Reverse
    84
  - Driving on Slippery Surfaces
    85
  - Driving Uphill
    88
  - Driving Downhill
    90
  - Turning Around on a Hill
    91
  - Driving over Obstacles
    94
  - Driving through Water
    96
  - Hauling Cargo
    97
- Emission Control Systems
  99
- Exhaust Emission Control System
  100
- Maintenance
  101
  - Periodic Maintenance Chart
    102
  - Lubrication Guide
    109
  - Engine Oil
    111
  - Engine Oil Check
    112
  - Engine Oil Change
    113
  - Fuel Filter
    116
  - Transmission Oil Check
    117
  - Gearcase Capacity
    118
  - Spark Plugs
    119
  - Vehicle Immersion
    121
  - Cylinder Head Torque
    121
  - Cvt Drying
    124
  - Spark Arrester
    125
  - Speed Control System
    129
  - Throttle Cable Adjustment
    131
  - Brake Freeplay
    132
  - Brake Lever Travel
    136
  - Toe Alignment
    137
  - Steering Inspection
    139
  - Shock Spring Adjustment
    139
  - Camber and Caster
    139
  - Drive Chain
    140
  - Drive Chain Slack
    141
  - Drive Chain Slack Adjustment
    142
  - Air Filter
    143
  - Handlebar Adjustment
    145
  - Wheel Removal
    147
  - Tire Tread Depth
    147
  - Wheel Installation
    148
  - Axle and Wheel Nuts
    149
  - Wheel Hub Tightening
    149
  - Transporting the Atv
    164
- Specifications
  165
- POLARIS Products
  171
- Troubleshooting
  173
- Warranty
  179
- Maintenance Log
  194
Index
198

Polaris Sportsman 90 Owner's Manual (186 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 1.88 MB

Welcome

6
- Table of Contents
  8
Safety

10
- Safety Training
  10
- Equipment Modifications
  18
Youth Section

20
- Know Your ATV
  21
- Pre-Ride Check
  28
- Riding Rules
  31
Adult Section

36
- Safety Decals
  37
- Driver Warnings
  50
- Vehicle Identification Numbers
  73
- Features and Controls
  74
  - Throttle Lever
    78
  - Shift Lever (90Cc Models)
    79
  - Parking Brake
    83
  - Oil System
    85
  - Fuel System
    86
  - Footwell Riser
    90
- Break-In Period
  91
- Pre-Ride Inspections
  93
- Daily Pre-Ride Inspection
  93
- Starting the Engine
  94
- Stopping the Engine
  96
- Driving Safely
  97
  - Driving Procedure
    99
  - Making Turns
    100
  - Driving on Slippery Surfaces
    101
  - Driving Uphill
    103
  - Driving Across Hillsides
    105
  - Turning Around on a Hill
    107
  - Driving Downhill
    109
  - Parking on a Hill or Incline
    110
  - Driving through Water
    111
  - Driving over Obstacles
    113
- Hauling Cargo
  115
- Emission Control
  118
  - Spark Arrestor
    118
  - Pvt System
    119
- Maintenance
  119
  - Maintenance Chart Key
    125
  - Lubrication Recommendations
    129
  - Rear Spring Adjustment
    135
  - Handlebar Adjustment
    135
  - Front Wheel Hub Tightening
    137
  - Steering Inspection
    141
  - Toe Alignment
    141
  - Camber and Caster
    142
  - Throttle Cable Adjustment
    143
  - Brake Freeplay
    143
  - Brake Freeplay Specifications
    143
  - Brake Lever Travel
    144
  - Brake Adjustment
    144
  - Air Cleaner
    145
  - Carburetor Adjustments
    146
  - Spark Plugs
    147
  - Cylinder Head/Cylinder Base Fastener Torque
    149
  - Gearcase Lubrication
    149
  - Gearcase Oil Change
    150
  - Wheel Removal
    152
  - Wheel Installation
    153
  - Brakelight Lamp Replacement
    158
  - Cleaning and Storage
    161
- Specifications
  165
- Polaris Products
  171
- Troubleshooting
  173
- Warranty
  179
  - Recommended Lubricants
    182
  - How to Get Service
    183
Index

185

Polaris Sportsman 90 Service Manual (109 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 51.27 MB

General Information Chapter 1 1 General Information/ Maintenance

5
- Scrambler
  2
- Scrambler
  3
- Table of Contents
  5
- Chapter 1 General Information/ Maintenance
  6
- Serial Number Location
  6
  - Sportsman
    9
- Specifications
  9
- Inspection Schedule
  10
- Paint Codes
  10
- Publication Numbers
  10
- Lubricant and Maintenance Products
  11
- Special Tools
  11
- Standard Torque Specifications
  11
- Glossary of Terms
  14
- Youth Models
  15
- Vehicle Inspection/Adjustments
  16
- Transmission Lubrication
  18
- Idle Speed Adjustment
  19
- Throttle Operation / Air Screw Adjustment
  19
- Throttle Cable / ETC Adjustments
  20
- Oil Pump Adjustment / Bleeding
  21
  - Oil Pump Bleeding
    21
- Fuel System
  22
  - Oil Tank
    23
  - Carburetor Draining
    23
- Oil Pump Troubleshooting
  22
- Air Filter Service
  24
- Compression Test
  24
  - Wheel/Hub/Spindle Torque Table
    24
  - Wheel Removal Front/Rear
    24
  - Wheel Installation
    25
  - Tire Pressure
    25
  - Tire Inspection
    25
  - Wheel Alignment
    26
  - Camber and Caster
    26
Chapter 2 Engine/Transmission/Cvt

29
- Engine / Transmission / CVT
  29
- CVT Exploded View
  30
- Special Tools
  30
- Torque Specifications
  30
- Engine Removal
  31
- Engine Disassembly
  32
  - Engine Installation
    32
- Transmission Service
  38
- Engine Component Inspection
  39
  - Electrical
    41
  - Scrambler
    42
  - Scrambler
    43
- Engine Reassembly
  46
- Starter Drive One Way Clutch
  52
Fuel System/Carburetion Chapter 3 Carburetion

55
- Jetting Guidelines
  57
- Carburetor Operation
  58
  - Sportsman
    58
- Carburetor Specifications
  58
- CHAPTER 3 CARBURETION Carburetorexploded View
  58
- Optional Main Jets
  58
- Float System
  59
- Jet Needle / Needle Jet / Throttle Opening
  60
- Jet Needle/ Needle Jet 3/8--3/4 Throttle
  62
- Pilot System
  62
- SLIDE CUTAWAY (1/8-3/8 Throttle)
  62
- Fuel Delivery
  63
  - Main System
    63
- Needle and Seat Leakage Test
  64
- Carburetor Float Bowl Draining
  65
- Cold Weather Starting Procedure
  66
- Troubleshooting
  67
Chapter 4 Body/Steering/Suspension

69
- Engine Mounting
  71
- Torque Specifications / Special Tools
  71
- Shocks and Springs
  72
- Suspension A-Arms
  72
- Steering
  73
- Front Brake
  74
- Rear Brake and Axle
  75
- Fuel and Oil Tank
  77
- Scrambler Front and Rear Cab
  78
- Sportsman Front and Rear Cab
  78
- Sportsman Handlebar Assembly
  79
- Scrambler Handlebar Assembly
  81
Electrical Chapter 5 Electrical

85
- Chapter 5 Electrical
  86
- Electrical Service Notes
  86
- Special Tools
  86
- Brakelight Bulb Replacement
  87
  - Battery Activation
    88
- Battery Inspection/ Removal
  89
  - Battery Testing
    89
- Battery Installation
  89
- Load Test
  89
- Charging Procedure
  90
  - Routine Maintenance
    90
- Off Season Storage
  90
- Charging System Testing
  92
- Alternator Output Test
  93
- Charging System Break Even Test
  93
- Current Draw / Key off Test
  93
- Starter System Troubleshooting / Voltage Drop Test
  94
  - Spark Plug
    94
- Brush Inspection/ Replacement
  96
- Starter Motor Disassembly
  96
- Armature Testing
  97
- Starter Assembly
  97
- Electronic Throttle Control (ETC)
  98
- Cranking Tests
  99
- Ignition System Troubleshooting
  100
  - Coil Testing
    100
  - Quick Reference Diagram
    101
  - Scrambler 90/Sportsman 90/Predator 90 Wiring Diagram
    103

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Index

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