Polaris Offroad Vehicle Sprotsman 90 User Manual

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Welcome

Dear Parents:

We believe your children should have the opportunity to enjoy The Way Out experience

along with you. We’ve provided this owner’s manual to assist you and your children in

learning about safe operation and care of your new ATV. Please review the information in

this manual with any child who may operate the ATV. Help your children learn to operate

the ATV with safety as a top priority. Help them also learn to show respect for our

environment and for the rights of others while operating the ATV.

Children differ in skills, physical abilities and judgement. Some children may not be able to

operate an ATV safely. Always supervise your child’s use of the ATV, and permit continued

use only if you determine that your child has the ability and maturity to operate the ATV

safely. Never allow a child to operate the ATV without adult supervision.

The preventive maintenance program outlined in this manual is designed to ensure that all

critical components on your child’s ATV are thoroughly inspected at various intervals. For

safe and enjoyable operation of the vehicle, be sure to follow all of the instructions and

recommendations in this manual. If you have any questions about the ATV, contact a

Polaris dealer for assistance.

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Welcome

Dear Children:

Before you ride your new Polaris ATV, there are some important things that you need to

know. Your parents and Polaris want you to enjoy riding your new ATV, and that’s why

you need to read and understand the information in your owner’s manual.

Ask your parents to explain anything you don’t understand, and pay close attention to the

warnings and instructions you read. Your safety and the safety of others is the most

important thing to think about at all times.

As the driver of the ATV, you must learn how to keep yourself and those around you safe

while you’re riding. So read your manual, and then enjoy riding your new Polaris ATV!

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information at the time of publication. Due to constant improvements in the design and quality of production

components, some minor discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can

be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained

within, whether whole or in part, is expressly prohibited. Printed in Taiwan.

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Table of Contents

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

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

Driver Warnings . . . . . . . . 47

Vehicle ID Numbers . . . . 74

Features and Controls . . 77

Break-in Period . . . . . . . . 92

Pre-Ride Inspections . . . 94

Starting the Engine . . . . . 96

Driving Safely . . . . . . . . . . 98

Hauling Cargo . . . . . . . . 115

Emission Control . . . . . . 119

Maintenance . . . . . . . . . 120

Specifications . . . . . . . . . 164

Polaris Products . . . . . . 170

Troubleshooting . . . . . . . 172

Warranty . . . . . . . . . . . . . 178

Welcome . . . . . . . . . . . . . . . . . 1

Safety . . . . . . . . . . . . . . . . . . . . 7

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

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

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

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

Index . . . . . . . . . . . . . . . . . . . 184

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Safety

Understand the Warnings

Always follow the age guidelines for your ATV. Never allow a younger child to ride on or

drive the ATV. Make sure all operators understand all warnings and the owner’s manual

before driving the ATV.

Know Your ATV Before Riding

Parents must help their children learn the proper and safe way to ride an ATV. Read the

owner’s manual with your children before starting the engine for the first time, and review

it with them periodically afterwards.

Safety Training

When you purchased this ATV, your Polaris dealer offered a hands-on safety training course

that covers all aspects of ATV safety. In addition, you were provided with printed material

and a video that instructs operators on safe operating procedures. You should review this

information with your child on a regular basis. If you purchased a used Polaris ATV from a

party other than a Polaris dealer, you can request this free safety training from any

authorized Polaris dealer.

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Safety

The following signal words and symbols appear throughout this manual and on your

vehicle. Your safety is involved when these words and symbols are used. Become familiar

with their meanings before reading the manual.

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

potential for personal injury.

WARNING

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

or death.

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Safety

CAUTION

The safety alert caution indicates a potential hazard that may result in minor personal

injury or damage to the vehicle.

CAUTION

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

NOTE:

A note will alert you to important information or instructions.

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Safety

WARNING

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

A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles

differently than other vehicles such as motorcycles and cars. A collision or rollover

can occur quickly, even during routine maneuvers like turning, or driving on hills or

over obstacles, if you fail to take proper precautions.

Read and understand the owner’s manual and all warnings before operating a

Polaris ATV.

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Safety

S Read this manual and all labels carefully and follow the operating procedures described.

S 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.

S Always follow the age guidelines for your machine: 90cc models are designed for chil-

dren not less than 12 years of age and 50cc models are designed for children not less than

6 years of age. No child under the age of 16 should ride any ATV designed and sold for

an adult.

S Do not allow other children to ride this ATV unless they have read the manual, seen the

instructional video and taken and passed a Polaris approved riding skill test.

S Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways,

parking lots and streets.

S Never operate an ATV on any public street, road or highway, including dirt or gravel

roads.

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Safety

S Never operate an ATV without wearing an approved helmet that fits properly. You

should also wear eye protection (goggles or face shield), gloves, boots, long-sleeved shirt

or jacket, and long pants.

S Never consume alcohol or drugs before or while operating this ATV.

S Never operate at excessive speeds. Always travel at a speed which is proper for the ter-

rain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts.

S Always inspect your ATV each time you use it to make sure it is in safe operating condi-

tion. Always follow the inspection and maintenance procedures and schedules described

in this manual.

S Always keep both hands on the handlebars and both feet on the footrests of the ATV dur-

ing operation.

S Always go slowly and be extra careful when operating on unfamiliar terrain. Always be

alert to changing terrain conditions when operating the ATV.

S Never operate on excessively rough, slippery or loose terrain.

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Safety

S Always follow proper procedures for turning as described in this manual. Practice turn-

ing at low speeds before attempting to turn at faster speeds. Do not turn at excessive

speed.

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

an accident.

S Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on

smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills as described in this manual. Check

the terrain carefully before you start up any hill. Never climb hills with excessively slip-

pery or loose surfaces. Shift your weight forward. Never open the throttle suddenly or

make sudden gear changes. Never go over the top of any hill at high speed.

S Always follow proper procedures for going down hills and for braking on hills as de-

scribed in this manual. Check the terrain carefully before you start down any hill. Shift

your weight backward. Never go down a hill at high speed. Avoid going down a hill at

an angle which would cause the vehicle to lean sharply to one side. Go straight down the

hill where possible.

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Safety

S Always follow proper procedures for crossing the side of a hill as described in this manu-

al. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the

uphill side of the ATV. Never attempt to turn the ATV around on any hill until you have

mastered the turning technique described in this manual on level ground. Avoid crossing

the side of a steep hill if possible.

S 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 back-

wards, follow the special procedure for braking described in this manual. Dismount on

the uphill side or to either side if pointed straight uphill. Turn the ATV around and re-

mount, following the procedure described in this manual.

S Always check for obstacles before operating in a new area. Never attempt to operate

over large obstacles, such as large rocks or fallen trees. Always follow proper procedures

when operating over obstacles as described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly

and be very cautious in order to reduce the chance of skidding or sliding out of control.

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Safety

S Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water

which exceeds the recommended maximum depth (pg. 112), go slowly, balance your

weight carefully avoiding sudden movements, maintain a slow and steady forward mo-

tion, do not make sudden turns or stops, and do not make sudden throttle changes.

S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If

necessary apply them lightly several times to let friction dry out the pads.

S Always use the size and type tires specified in this manual. Always maintain proper tire

pressure as described in this manual.

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

S Never exceed the stated load capacity for an ATV.

S Always remove the ignition key when the vehicle is not in use to prevent unauthorized

use or accidental starting.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety

Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.

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Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we

strongly recommend that consumers do not install on a Polaris ATV any equipment that

may increase the speed or power of the vehicle, or make any other modifications to the

vehicle for these purposes. Any modifications to the original equipment of the vehicle

create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your Polaris ATV is terminated if any equipment has been added to the

vehicle, or if any modifications have been made to the vehicle, that increase its speed or

power.

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

ATV. Use only Polaris-approved accessories, and familiarize yourself with their function

and effect on the ATV.

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Youth

Section

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Know Your ATV

PARENTS: Polaris Youth ATVs are equipped with an electronic 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 139.

These units are not designed for adult use. Serious damage to the vehicle may occur if the

maximum rider weight capacity is exceeded. See the specifications section beginning on

page 164 for your ATV’s capacity.

CHILDREN: Before you ride your new Polaris ATV, there are some important things that

you need to know. Your safety and the safety of others is the most important thing to think

about at all times. As the driver of the ATV, you must learn how to keep yourself and those

around you safe while you’re riding.

Pay attention when you see this symbol:

This is the safety alert symbol. When you see this symbol on your

ATV or in this manual it means PAY ATTENTION because you

could die or be seriously injured if you don’t follow the instructions.

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Know Your ATV

Before you have an adult start the engine for you for the first time, let’s learn about the

controls on your new ATV.

1. Engine Stop Switch - When the engine is running, push this button down to shut the

engine off quickly. The button must be up before you can start the engine again.

2. Horn Button (90 cc models) - Press the horn button to sound the horn.

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

go forward. Always make sure the throttle control does not stick before you drive your

ATV. Read more about it on page 25.

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Know Your ATV

4. Kick-Start Lever - If your battery is too

weak to start your ATV, you can push down

on the kick-start lever with your foot to

start the engine. Have an adult show you

how it works. Read more about how to use

the kick-start on page 90.

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Know Your ATV

5. Gas Cap - The gas cap has to be taken off

when an adult puts gas in your ATV. Never

take the gas cap off. Always make sure it’s

tightly closed.

Always have an adult put

gas in your ATV. Never try

to do it yourself.

6. Seat Latch - To remove the seat, pull up

on the seat latch on the lefthand side of the

seat. To replace the seat, set it in place and

push down on the seat above the latch.

Always make sure the seat is locked in

place before riding.

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Know Your ATV

7. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop

the ATV. The lefthand lever (7A) controls the rear brake. The righthand lever (7B)

controls the front brake. Always squeeze both brake levers at the same time.

Always squeeze both brakes at the same time or you could lose

control of the ATV and be seriously injured.

Always take your thumb off the throttle lever when you squeeze the

brake levers.

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Know Your ATV

8. 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.

9. Tether Strap and Switch - The tether strap must always be attached snugly to your

right wrist and to your ATV every time you drive. If you fall off your ATV, the tether

strap will pull away from the switch and the engine will stop.

Never ride without the tether strap attached to your right wrist and to

your ATV. Be careful not to let the cord get tangled around the

handlebars or any part of your body.

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Know Your ATV

Let’s review the three ways to stop your ATV:

1. Push the stop switch down.

2. Pull off the tether strap.

3. Turn the key off.

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Pre-Ride Check

We’re almost ready to have an adult start your ATV. But before the ATV is started for the

first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must

have an adult help you check some things on your ATV before starting it. Let’s learn about

these things now.

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

handlebar and then letting go. The lever should come right back to where it was before

you pushed it. If it comes back slowly or stays close to the handlebar, the ATV has a

sticky throttle. This means that something is wrong or broken and must be fixed before

you can ride your ATV safely.

Never start the engine if you have a sticky throttle. You could be

seriously hurt if you ride with a sticky throttle. Have an adult or your

Polaris dealer fix the throttle before you ride.

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Pre-Ride Check

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

handlebar and then letting go. They should come right back to where they were before

you squeezed. If they go back slowly or stay close to the handlebar, your ATV has sticky

brakes. They must be fixed before you can ride your ATV safely.

Never start the engine if your ATV has sticky brakes. You could be

seriously hurt if you ride with sticky brakes. Have an adult or your

Polaris dealer fix the sticky brakes before you ride.

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

own gasoline. This must always be done by an adult. Before anyone adds gasoline to

your ATV they must read the instructions and warnings on page 86 of this manual.

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

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Pre-Ride Check

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

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

after it has been running and it can burn your skin if you touch it. Children must never

check the oil on their own. An adult should always be in charge of keeping the gas and

oil levels at the full marks.

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

three ways to stop your ATV are working the way they should. Do you remember what

they are? If you can’t remember the three ways to stop your ATV, go back to page 24

and review. Then have an adult help you start your ATV and practice stopping the en-

gine all three ways.

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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

driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.

The adult with you is your teacher. Always pay attention to what your teacher says so you

can learn how to always drive safely.

Let’s learn how to ride!

Always follow the safe riding rules found on the next pages. You or

others around you could be seriously hurt or killed if you don’t follow the

safe riding rules.

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Riding Rules

" Always wear the right kind of clothing and safety gear when riding your ATV.

1. Helmet: Your helmet is very important for safe riding.

A helmet can prevent a severe head injury.

2. Eye Protection: Always wear shatterproof goggles or a

helmet face shield, and always keep them clean so you can

see where you’re driving.

3. Gloves: Wear gloves to protect your hands from sun and

wind. Gloves will also protect your hands from scrapes and

scratches.

4. Boots: Wear sturdy boots to keep your feet dry. Boots

will also protect your feet and ankles from scrapes and

scratches.

5. Clothing: Make sure your clothing fits properly. If it’s

too small, it could keep you from moving easily when you

shift your weight. If it’s too big, it could hang down and

get caught in a moving part.

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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. Never carry

a passenger. A passenger will make the ATV

harder to drive. You you may lose control and

hurt yourself and your passenger.

" Always drive your ATV while sitting down.

Keep both hands on the handlebars and keep

both feet on the footrests.

" Always be alert and pay attention to where you’re driving. Pay attention to other drivers,

and be even more careful around them because you don’t know what they’re going to do.

" Never follow another ATV too closely. You need lots of time and space to stop your

ATV.

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Riding Rules

" Never ride alone. An adult should always be watching you in case you need help. Al-

ways 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.

" Don’t ride at night. Your ATV doesn’t have lights that are safe for driving in the dark.

" Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away

from them.

" Never ride on frozen water. You could get hurt or you could even die. All ice can be

dangerous!

" Ride your ATV only where you know it is safe to drive and where you have permission

to drive. Be careful of the things around you.

" Always be a polite driver. (No driving through the flower garden or over the little trees

you planted.)

" Always do your best to help take care of nature.

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Respect your ATV;

respect your environment;

and you will earn

the respect of everyone.

Enjoy riding your new Polaris ATV!

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Adult

Section

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Safety Decals

Warning and safety decals have been placed on the ATV for the protection of the operator.

Read and follow the instructions on each decal carefully. If any safety decal becomes

illegible or comes off, contact your Polaris dealer for a free replacement. The part number

is printed on the decal.

WARNING

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Safety Decals

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; at speeds too fast for your skills or

the conditions; on public roads - a collision can occur with another vehicle; with a passenger

- passengers affect balance and steering and increase risk of losing control.

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 DEALER FOR

A REPLACEMENT.

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Safety Decals

Predator 50 Age Warning Decal

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.

Never operate this ATV on HILLS steeper than 15

degrees 15°. To prevent flipover on hilly terrain,

use throttle and brakes gradually.

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Safety Decals

Predator 50 Age Warning Decal

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.

S Never operate this ATV on HILLS steeper than 15 degrees

15°. To prevent flipover on

hilly terrain, use throttle and brakes gradually.

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Safety Decals

Predator 90/Sportsman 90 Age Warning Decal

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.

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.

Never operate this ATV on HILLS steeper than

15 degrees 15°. To prevent flipover on hilly

terrain, use throttle and brakes gradually.

7079091

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Safety Decals

Predator 90/Sportsman 90 Age Warning Decal

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.

S Never operate this ATV on HILLS steeper than 15 degrees

15°. To prevent flipover on

hilly terrain, use throttle and brakes gradually.

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Safety Decals

(Predator 50/90)

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING can cause

loss of control, resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT ___ REAR ___

Maximum Weight Capacity (Gross Vehicle Weight)

INCLUDING MACHINE, DRIVER AND CARGO IS _____ LBS.

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Safety Decals

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 423 LBS.)

Reduce speed and allow greater distance for braking when

carrying cargo. Overloading or carrying tall, off-center, or unse-

cured loads will increase your risk of losing control. Loads

should be centered, carried as low as possible, and firmly se-

cured to the racks. With dual racks, load distribution 1/3 front

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.

(Sportsman 90)

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Safety Decals

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Safety Decals

ATTENTION

Operation of this vehicle without the filter

Specific carburetor jetting and

element will severely damage the engine.

adjustments are required depending

on temperature and altitude. See your

Owner’s Manual.

Clean air filter often, more frequent clean-

ing required in dusty conditions.

Factory Setting:

40° to 80° F. at 0-3000 feet.

(5° to 27° C. at 0-900 meters)

(on air filter box)

(on rear of seat)

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Safety Decals

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Safety Decals

WARNING

Moving parts hazard under belt-clutch guard. To prevent serious injury, do

not operate vehicle with guard removed.

Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM which can result in serious injury or death.

MANUFACTURED

IN TAIWAN

WARNING

DATE:

DO NOT TOW FROM RACK OR BUMPER. Vehicle

VIN:

damage or tipover may result causing severe injury or

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS

NOT INTENDED FOR USE ON PUBLIC ROADS.

death.

Maximum Rack Loads: Front 10 lbs.; Rear 20 lbs.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN

QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR

LES CHEMINS PUBLICS.

(Sportsman 90)

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NOTES

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Driver Warnings

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,

so be sure to explain to your young driver that

the following hazards MUST be avoided at all times.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does not know how to

operate the ATV properly in different situations and on different types of terrain.

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.

For more information about the training course, contact an authorized ATV dealer or

call Polaris at 1-800-342-3764.

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Driver Warnings

WARNING

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.

HOW TO AVOID THE HAZARD

Follow the age guidelines printed on your machine.

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Driver 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. The long seat is to allow

the operator to shift position as needed during

operation. It is not for passengers.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV on paved surfaces, including

sidewalks, 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

possible. If you must ride on a paved surface, go slowly

and do not make sudden turns or stops.

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Driver 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 public streets, roads and highways.

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Driver Warnings

WARNING

POTENTIAL HAZARD: Operating this ATV without wearing an approved helmet,

eye protection and protective clothing.

WHAT CAN HAPPEN: Operating without an approved helmet increases your

chances of a severe head injury or death in the event of an accident.

Operating without eye protection can result in an accident and increases your

chances of a severe injury in the event of an accident.

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.

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Driver 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.

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Driver Warnings

WARNING

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; and your experience.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Attempting wheelies, jumps and other stunts.

WHAT CAN HAPPEN

Attempting stunts increases the chance of an

accident, including an overturn.

HOW TO AVOID THE HAZARD

Never attempt wheelies, jumps, or other stunts.

Avoid exhibition driving (don’t show off).

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Driver Warnings

WARNING

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.

Always follow the inspection and maintenance procedures and schedules

described in the Owner’s Manual.

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Driver 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.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the footrests of your

ATV during operation.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Failure to use extra care when operating this ATV

on unfamiliar terrain.

WHAT CAN HAPPEN

You can come upon hidden rocks, bumps, or

holes, without enough time to react.

Could result in the ATV overturning or going out of

control.

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.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Failure to use extra caution when operating on

excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slippery or loose

terrain could cause loss of traction or loss of control,

which could result in an accident or overturn.

HOW TO AVOID THE HAZARD

Do not operate on excessively rough, slippery or loose terrain until you’ve learned

and practiced the skills necessary to control the ATV on such terrain.

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

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Driver Warnings

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control and lead to a collision or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the owner’s manual.

Practice turning at slow speeds before attempting to turn at faster speeds.

Never turn at excessive speed.

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Driver Warnings

WARNING

POTENTIAL HAZARD: Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for climbing hills

as described in the Owner’s Manual beginning on

page 104.

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. An obstacle, a sharp drop, or another vehicle or

person could be on the other side of the hill.

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Driver Warnings

WARNING

POTENTIAL HAZARD: Going down a hill improperly.

WHAT CAN HAPPEN

Driving downhill improperly could cause loss of control or

ATV overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for going down hills as

described in the Owner’s Manual. See page 110.

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. Go straight down the hill when possible.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Improperly crossing hills and turning on hills.

WHAT CAN HAPPEN

Improperly crossing or turning as hills could

cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Never try to turn the ATV around on any hill until you’ve

mastered the turning technique (on level ground) as

described in the owner’s manual. See page 108. Use

extra caution when turning on any hill. Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s manual. Avoid hills with

excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

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Driver Warnings

WARNING

POTENTIAL HAZARD: Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN HAPPEN: The ATV could overturn.

HOW TO AVOID THE HAZARD

Maintain steady speed when climbing a hill.

If you lose all forward speed: Keep your weight uphill. Apply the

front brakes gradually (right lever). When fully stopped, apply the

rear brake as well (left lever) and then lock the parking brake.

If you begin rolling backwards: Keep weight uphill. Never apply engine power. Never

apply the rear brake while rolling backwards. Apply the front brake slowly. When fully

stopped, apply rear brake as well, and then lock the parking brake. Dismount on uphill

side, or to either side if pointed straight uphill. Turn the ATV around and remount,

following the procedure described in the Owner’s Manual. See page 108.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly, the ATV could overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel slowly and use extra caution to reduce the

chance of skidding or sliding out of control.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen trees when possible. If

unavoidable, use extreme caution and always follow proper procedures as outlined in

the owner’s manual.

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Driver 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.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Operating the 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 or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water. If it’s unavoidable to enter

water that exceeds the recommended maximum depth (see page 112), travel slowly,

balance your weight carefully, avoid sudden movements, and maintain a slow and

steady forward motion. Do not make sudden turns or stops, and do not make sudden

throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving

water. If necessary, apply them several times to let friction dry out the pads.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires, or with improper or uneven tire pressure.

WHAT CAN HAPPEN

Use of improper tires, or operation of the ATV with improper or uneven tire pressure,

could cause loss of control or accident.

HOW TO AVOID THE HAZARD

Always use the size and type of tires specified in the owner’s manual for the ATV.

Always maintain proper tire pressure as stated in the specifications section of the

owner’s manual.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Overloading the ATV.

WHAT CAN HAPPEN

Overloading the ATV could cause changes in handling, which could lead to an

accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

If equipped with racks, cargo should be properly distributed and securely attached.

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Driver Warnings

WARNING

After a rollover or an accident, have a qualified service dealer check the complete

machine including, but not limited to, brakes, throttle and steering for possible damage.

WARNING

Safe operation of this rider active vehicle requires good judgement and physical skills.

Persons with cognitive or physical disabilities who operate this vehicle have an increased

risk of overturns and loss of control which could result in severe injury or death.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in

serious injury or death. Always remove the ignition key when the vehicle is not in use.

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Driver Warnings

WARNING

POTENTIAL HAZARD

Operating the ATV with improper modifications.

WHAT CAN HAPPEN

Improper installation of accessories or modification of the ATV may cause changes in

handling which could lead to an accident.

HOW TO AVOID THE HAZARD

Never modify the ATV through improper installation or use of accessories. All parts and

accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent

components designed for use on this ATV and should be installed and used according

to approved instructions. See your authorized Polaris ATV dealer for more information.

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Vehicle Identification Numbers

The frame vehicle identification number (VIN) and engine

serial number (1) are important for model identification

when registering your vehicle, when obtaining insurance,

and when ordering replacement parts. In the event your

vehicle is stolen, these numbers are essential to the

recovery and identification of your vehicle.

The Predator 50 VIN is located on the righthand lower

frame tube. The Predator 90 and Sportsman 90 VIN is

located on the righthand front upper shock mount.

Remove the spare key and store it in a safe place. If both keys are lost, see your Polaris

dealer.

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Vehicle Identification Numbers

NOTE: Record your vehicle’s ID numbers and key number (3) in the spaces provided.

Frame VIN (on the front of the frame below the steering post):

Vehicle Model Number:

Engine Serial Number (on the left side of the engine crankcase):

Key Number:

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NOTES

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Features and Controls

Main Switch (A)

The main switch is located on the pod. This switch is operated with a key and must be

turned clockwise to the ON position before starting the engine.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in

serious injury or death. Always remove the ignition key when the vehicle is not in use.

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Features and Controls

Engine Stop Switch (B)

The stop switch (B) is located on the top of the left handlebar. The engine will not start or

run when the stop switch is down, in the OFF position. Its purpose is to provide the

operator with a quick means of engine shutdown in case of stuck throttle or other

emergency. NOTE: Both the main switch and the emergency engine stop switch shut off

all electrical power to the entire vehicle. To stop the engine quickly, push the stop switch

down.

Choke Lever (C)

The choke lever (C) is located on the bottom of the left handlebar. The choke is used when

starting a cold engine. Push the choke lever to the left before starting the engine. When the

engine starts, gradually return the choke lever to the OFF position as the engine warms up

and runs smoothly.

Horn Button (D)

The horn button is located on the lefthand control (Sportsman 90 and Predator 90).

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Features and Controls

Engine Start Button (E)

The start button is located slightly above the choke lever. To start the engine, make sure

the tether strap 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 button up to the ON

position and press the start button.

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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.

Failure to check or maintain proper operation of the throttle system can result in

an accident if the throttle lever sticks during operation. Always check the lever for

free movement and return before starting the engine. Also check occasionally

during operation.

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Features and Controls

Throttle Lever

Engine speed and vehicle movement are

controlled by pressing the throttle lever (A).

The throttle lever is spring loaded. 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. If the throttle cable should

stick in an open position when the operator releases the throttle

lever, the engine will stop and power to the rear wheels will cease.

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.

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Features and Controls

Brakes

To activate the rear brake, squeeze the lefthand lever (A) toward the handlebar. The front

brakes are activated by squeezing the lever (B) on the righthand handlebar.

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.

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Features and Controls

Brakes

Setting the Parking Brake

1. Squeeze the lefthand brake lever (A).

2. Push the park brake lock (B) down.

This will prevent the lever from

returning to the released position.

3. To release the parking brake lock,

squeeze and release the brake lever.

The parking brake will release

automatically.

WARNING

Operating the ATV while the parking brake is engaged could cause an accident

resulting in serious injury or death. It could also result in driveline or engine damage.

Always be sure to disengage the parking brake before operating the ATV.

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Features and Controls

Brakes

Parking Brake

NOTE: This vehicle has a PVT system that’s always in forward. Always lock the park

brake before starting the engine.

Always lock the parking brake whenever the vehicle is left unattended.

Since the transmission is always in forward gear, activating the throttle to warm the engine

will make the machine move forward if the park brake is not locked.

After the engine has warmed enough for operation, release the park brake and gently apply

the throttle to move forward.

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Features and Controls

Lights

WARNING

Polaris Youth ATVs are not equipped with lights. The ATVs are 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. Do not operate this ATV after dark.

Indicator Lights

Each Polaris ATV has different indicator lights. Your model has a low oil warning light.

When the red dot is illuminated, it means the oil level is getting too low.

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Features and Controls

Fuel System

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline.

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

S Do not smoke or allow open flames or sparks in or near the area where refueling

is performed or where gasoline is stored.

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

S If gasoline spills on your skin or clothing, immediately wash it off with soap and

water and change clothing.

S Never start the engine or let it run in an enclosed area. Engine exhaust fumes are

poisonous and can cause loss of consciousness or death in a short time.

S Turn the fuel valve off whenever the ATV is stored or parked.

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Features and Controls

Fuel System

WARNING

The engine exhaust from this product contains

chemicals known to cause cancer, birth defects

or other reproductive harm.

Operate this vehicle only outdoors or in

well-ventilated areas.

Gas Cap

The fuel tank filler cap (A) is located directly below

the handlebars. The tank has a capacity of 1.3

gallons (5 liters). Use unleaded gasoline with a

minimum pump octane of 87.

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Features and Controls

Fuel System

Fuel Valve

RES

The fuel valve is located on the lefthand

side of the ATV. It has three positions:

OFF: For vehicle storage and when

transporting.

OFF

ON: For normal operation.

RES: For reserve supply if main supply

is exhausted.

NOTE: There’s about a 7-10 mile (11-16 km)

range on reserve gas. Always refill the gas

tank as soon as possible after using the main

Sportsman

Predator

supply. Always return the valve to the ON position after refueling.

Fuel Filter

The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by

your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel

filter.

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Features and Controls

Oil System

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage.

We recommend the use of Polaris VES II Synthetic 2-cycle oil or Polaris Premium

Gold Synthetic 2-cycle oil. Never substitute or mix oil brands.

To avoid serious engine damage, always top off the oil level when refueling.

The oil tank (A) is located under

the seat and has a capacity of 1.1

quarts (1 liter). Always top off the

oil level when refueling.

NOTE: See page 21 for seat

removal instructions.

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Features and Controls

Kick-Start Lever

If the battery becomes too weak to start the engine, the

kick-start lever will allow you to start the engine until the

battery is serviced. Be sure the ATV is on a level surface

with the parking brake locked.

1. Fold out the kick-start lever (A) on the lefthand side of

the ATV.

2. Make sure the stop switch is in the RUN position and

turn the key to ON.

3. Place your foot on the kick-start, and then thrust your

heel downward to crank the engine.

4. After the engine has started, fold the kick-start lever back

into place. NOTE: A 10/12mm wrench is provided in

the tool kit for removing or installing the lever. If not

installed, make sure the rubber cap is installed on the kick-start shaft to protect the

rider. On 50cc models, store the kick-start lever under the seat (B) when it’s not

installed on the ATV.

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Features and Controls

Footwell Riser

The removeable footwell risers on the Predator

50 improve riding ergonomics and provide

comfort for shorter operators. An operator will

also have better control of the ATV when both

feet can remain firmly planted on either the

footwells or the risers. If the operator’s legs are

long enough to comfortably reach the footwells

without the risers, the risers can be removed.

1. Remove the rubber caps (A) covering

the screw access holes.

2. Remove the six screws (B) and nuts

securing the footwell riser (C) to the

footwell and remove the riser.

3. Reverse the procedure to reinstall the

footwell riser for shorter operators.

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Break-in Period

The break in period for your new Polaris ATV is the length of time it takes to use the first

tank of gas. No single action on your part is as important as following the procedures for a

proper break-in. Careful treatment of a new engine will result in more efficient

performance and longer life for the engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation will damage close-fitted

engine parts. Do not operate at full throttle or high speeds for extended periods during

the first three hours of use.

Use of any lubricants other than those recommended by Polaris may cause serious

engine damage. We recommend the use of Polaris lubricants for your vehicle.

1. Mix 6.4 ounces of recommended oil to two gallons of gasoline in an appropriate gas

container and fill the fuel tank as outlined on pages 86-87. NOTE: After the break-in

period the oil injection system provides the necessary engine lubrication without the

need for pre-mixed fuel.

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Break-in Period

2. Fill the oil tank with Polaris-recommended oil. NOTE: Always be sure to top off the

oil level whenever refueling.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride

inspection. See page 94.

6. After the first tank of pre-mixed fuel has been used, check to see if the oil level in the

oil tank has dropped, indicating that the oil pump is functioning properly. If the level

has not dropped, see your dealer for oil pump bleeding and then repeat the pre-mix

procedure.

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Daily Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death could result.

Always inspect the ATV before each use to ensure it’s in proper operating condition.

Use the following checklist to make sure the ATV is in proper working condition before

each use.

Item/Inspection Procedure

1. Tires - Check condition and pressures.

2. Fuel and oil tanks - Fill both tanks to their proper levels.

3. All brakes - Check operation and adjustment.

4. Throttle - Check for free operation and proper closing.

5. Brakelight - Check for proper operation.

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Daily Pre-Ride Inspection

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. 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 components or loose nuts/bolts

or fasteners.

12. Riding gear - Wear a helmet, goggles and protective clothing.

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Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can cause loss of

consciousness resulting in severe injury or death. Never run an engine in an

enclosed area.

CAUTION

Operating the ATV immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating.

1. Set the parking brake and turn the fuel tank valve to ON.

2. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist.

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Starting the Engine

NOTE: The choke is fully on when the lever is pushed completely to the left. The choke

is off when the lever is pushed completely to the right. The choke can be adjusted

gradually, depending on how much choke is needed for starting.

3. If the engine is cold, use full choke by pushing the choke lever all the way to the left.

A warm engine will not require the use of the choke.

4. Turn the engine stop switch to RUN, then turn the ignition key to ON. NOTE: Do not

press the throttle while starting the engine.

5. Squeeze the rear brake lever and press the starter button.

NOTE: The rear brake lever must be engaged or the engine won’t start.

6. Activate the starter for a maximum of five seconds, releasing the button when the

engine starts. If it doesn’t start, release the starter, wait five seconds, then activate for

another five seconds. Repeat until the engine starts.

7. If the engine slows or stops, position the choke lever half way to allow proper engine

warm up. Vary the RPM slightly with the throttle to aid in warm up.

8. When the engine idles smoothly, push the choke lever all the way to the right.

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Driving Safely

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV

riding requires special protective clothing for comfort and

to reduce the chance of injury.

1. Helmet

Your helmet is the most important piece of protective gear

for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet that meets or exceeds your

state’s safety standards and bears either the Department of

Transportation (DOT) label, the American National

Standards Institute label (ANSI z90.1), or the Snell

Memorial Foundation label.

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Driving Safely

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or a 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. Gloves

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

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with

kneepads and a jersey with shoulder pads provide the best protection.

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Driving Safely

Driving Procedure

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. Slowly depress the throttle with your

right thumb and begin driving.

Vehicle speed is controlled by the

amount of throttle opening.

6. Drive slowly, practice maneuvering

and using the throttle and brakes on

level surfaces.

100

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Driving Safely

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. To turn, steer in the direction of the

turn, leaning your upper body to the inside of the turn

while supporting your weight on the outer footrest.

This technique alters the balance of traction between

the rear wheels, allowing the turn to be made smoothly.

NOTE: Practice making turns at slow speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and

lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

101

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Driving Safely

Driving on Slippery Surfaces

WARNING

Failure to exercise care when operating on slippery surfaces can result in loss of tire

traction and cause loss of control, accident, and serious injury or death.

Never apply the brakes during a skid.

Do not operate on excessively slippery surfaces.

Always reduce speed and use additional caution.

102

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Driving Safely

Whenever riding on slippery surfaces such as wet trails

or loose gravel, or during freezing weather, follow

these precautions:

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.

103

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Driving Safely

Driving Uphill

WARNING

Braking and handling are greatly affected when operating in hilly terrain. Improper

procedure could cause loss of control or overturn and result in serious injury or

death.

Avoid climbing steep hills (15_ maximum).

Use extreme caution when operating on hills, and follow proper operating procedures

outlined in the owner’s manual.

104

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Driving Safely

Whenever traveling uphill, follow

these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed

and throttle opening.

6. Remain alert and be prepared to

take emergency action. This may

include quick dismounting of the

vehicle.

15_ Maximum

105

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Driving Safely

Driving Across Hillsides

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle

overturn, resulting in severe injury or death. Avoid crossing the side of a hill when

possible. Follow proper procedures as outlined in the owner’s manual.

106

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Driving Safely

Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If

you do enter into a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your

upper body weight uphill while

keeping your feet on the footrests.

3. Steer slightly into the hill to maintain

direction.

NOTE: If the vehicle begins to tip,

quickly turn the front wheel downhill, if

possible, or dismount on the uphill side

immediately!

107

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Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or overturn and result in

serious injury or death.

Avoid climbing steep hills (15_ maximum).

Use extreme caution when operating on hills, and follow proper operating procedures

outlined in the owner’s manual.

If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that

can be used when it’s necessary to turn around while climbing a hill is the K-turn:

1. Stop and lock the parking brake while maintaining body weight uphill.

2. Shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing

straight uphill.

108

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Driving Safely

4. Staying uphill of the ATV, turn the handlebars full left.

5. While holding the brake, release the parking brake lock and slowly release the brake,

allowing the ATV to roll around to your right until it’s pointing across the hill or

slightly downward.

6. Lock the parking brake and

remount the ATV from the uphill

side, maintaining body weight

uphill.

7. Restart engine, release the parking

brake, and proceed slowly,

8’

controlling speed with the rear

brake, until the ATV is on more

level ground.

Uphill

109

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Driving Safely

Driving Downhill

Whenever descending a hill, follow these

precautions:

1. Drive directly downhill.

2. Transfer your weight to the rear of the

vehicle.

3. Slow down.

4. Apply the front and rear brakes at the same

time, and very slightly, to aid in slowing.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death.

Always operate slowly when traveling downhill.

110

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Driving Safely

Parking on a Hill or Incline

Avoid parking on a hill or incline if

possible. If it’s unavoidable, follow these

precautions:

1. Turn the engine off.

2. Set the parking brake.

3. Always block the rear wheels on the

downhill side as shown in the

illustration.

4. Shut off the fuel supply.

111

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Driving Safely

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 (A). Follow these procedures

when operating through water:

1. Determine water depths before driving

through water.

2. If crossing a stream, choose a crossing

where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and

obstacles if possible.

4. After driving through water, dry the brakes by applying light pressure to the levers until

braking action is normal. If you do not perform this procedure, your brakes may be

ineffective.

112

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Driving Safely

Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in

deeper water than recommended, it’s critical to have it serviced as outlined in the

maintenance chart beginning on page 126. The following areas need special attention:

engine oil, gearcase oil, front and rear gearcases and all grease fittings.

CAUTION

Major engine damage can result from driving this ATV in deeper water than

recommended. If your vehicle becomes immersed or is operated in water that exceeds

the bottom of the footrests, take it to your dealer for service before starting the engine.

113

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Driving Safely

Driving Over Obstacles

Be alert! Look ahead and learn to read the

terrain you’re traveling on. Be constantly

alert for hazards such as logs, rocks and

low hanging branches.

WARNING

Severe injury or death can result if your vehicle comes in contact with a hidden obstacle.

Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.

114

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Hauling Cargo

The Sportsman 90 was designed to carry a certain amount of load. Never exceed the

weight capacities listed in the specifications section of the owner’s manual. Never carry

cargo on a Scrambler.

Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack)

and mounted as low as possible. When operating over rough or hilly terrain, reduce speed

and cargo weight to maintain stable driving conditions.

WARNING

Hauling cargo improperly can alter vehicle handling and may cause loss of control or

brake instability and result in serious injury or death. Always heed the warnings on

the following pages.

115

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Hauling Cargo

2/3 of Load

1/3 of Load

Front Rack

Rear Rack

S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING

WHEN CARRYING CARGO.

S CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on

the rear rack. When operating over rough or hilly terrain, reduce speed and cargo

to maintain stable driving conditions. Carrying loads on one rack only increases

the possibility of vehicle tip over.

S 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.

116

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Hauling Cargo

S 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.

S LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of the vehicle and

creates a less stable operating condition. When cargo loads are carried high on

the racks, the weight of the loads must be reduced to maintain stable operating

conditions.

S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS.

When handling off-centered loads which cannot be centered, securely fasten load

and operate with extra caution.

S EXTREME CAUTION MUST BE USED when operating with loads extending

over the rack sides. Stability and maneuverability may be adversely affected,

causing the machine to overturn.

S DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.

117

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NOTES

118

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Emission Control Systems

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect

compliance with state and local noise level requirements.

Spark Arrestor

Your Polaris ATV is not equipped with a spark arrestor approved by the USDA Forest

Service. Operating this ATV on U.S. public lands without a spark arrestor is in violation of

federal law.

119

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Maintenance

PVT System

WARNING

The PVT system rotates at high speeds, creating large amounts of force on clutch

components. Extensive engineering and testing has been conducted to insure the

safety of this product. However, as the owner you have the following responsibilities

to make sure this system remains safe:

Do not modify any component of the PVT system. Doing so may reduce its strength

so that a failure may occur at high speeds. This system has been precision balanced.

Any modification will cause the system to be out of balance, creating vibration and

additional loads on components.

S Routine maintenance is the responsibility of the owner. Always follow recom-

mended maintenance procedures. See your dealer!

S This PVT system is intended for use on Polaris products only.

S The PVT housing must be securely in place during operation.

Failure to comply with this warning can result in severe injury or death.

120

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Maintenance

PVT System

If the ATV is operated in dusty areas, clean the PVT filter more often than recommended

for normal conditions. 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. Allow the filter to air dry, then reinstall.

CAUTION

Exposure to salt water will cause corrosion to metal components. If your vehicle is

operated in salt water areas, rinse it off frequently with fresh water.

121

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Maintenance

Battery

The battery in your Polaris ATV is a sealed battery. The sealing strip cannot be removed.

Never add water to this type of battery.

Keep the battery terminals and connections free of corrosion. If cleaning is necessary,

remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon

baking soda and one cup water. Rinse well with tap water and dry off with clean shop

towels. Coat the terminals with dielectric grease or petroleum jelly.

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion

and cause serious injury or death. When removing the battery, always disconnect

the negative (black) cable first. When reinstalling the battery, always connect the

negative (black) cable last.

122

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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.

123

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Maintenance

Battery

Battery Installation and Connections

1. Set the battery in its holder.

2. Connect and tighten the red (positive) cable first.

3. Connect and tighten the black (negative) cable last.

4. Attach the hold-down strap.

5. Verify that cables are properly routed.

NOTE: When installing a new battery, make sure it’s fully charged prior to its initial use.

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.

Battery Storage

When the vehicle is placed in storage for three months or more, the battery should be

removed, stored out of the sun in a cool, dry place and tested monthly. Before reusing, take

the battery to your dealer for testing and recharging on a .5 amp battery charger.

124

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Maintenance

Periodic Maintenance Schedule

To help you perform routine maintenance, a tool kit is provided in the storage compartment

under the seat. Items included in the kit are:

S Spark plug wrench

S Screwdriver

S Tire pressure gauge

Maintenance intervals are based upon average riding conditions and an average vehicle

speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as

operation in wet or dusty areas, should be inspected and serviced more frequently.

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.

NOTE: Service and adjustments are critical. If you’re not familiar with safe service and

adjustment procedures, have a qualified dealer perform these operations.

125

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Maintenance

Periodic Maintenance Schedule

Hours of operation are based on a 10 mph average. If service is due at 20 hours, the

equivalent odometer reading would be 200 miles. Perform all services at whichever

reading is reached first.

WARNING

Improperly performing the procedures marked with a J could result in component

failure and lead to serious injury or death. Have an authorized Polaris dealer

perform these services.

Maintenance Chart Key

Perform these operations more often under severe use, such as in dirty or wet

conditions, to purge water or dirt contamination from grease fittings and other critical

components.

Dealer service item.

126

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Maintenance

Periodic Maintenance Schedule

Item to Inspect

Hours/

Miles

Frequency Remarks

Brake System

Tires

Pre-ride

Inspect

Wheels

Frame nuts, bolts,

fasteners

Inspect; tighten any loose hardware

Throttle

Pre-ride

10 hrs

Pre-ride

Monthly

Check for proper operation

Check level; fill oil when refueling

Inspect; clean

Engine stop switch

Engine oil

" Air Filter

" Steering

Check for free operation

Inspect

" Drive Chain

J Brake pad wear

Battery

Inspect periodically

20 hrs

Inspect terminals; clean

127

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Maintenance

Periodic Maintenance Schedule

Item to Inspect

Hours/

Miles

Frequency Remarks

Oil Pump Cable

50 hrs

6 months

Inspect; adjust; lubricate; replace if

required

Carburetor Float

Bowl

Drain bowl periodically and prior to

storage

Inspect; adjust; lubricate; replace if

necessary

J Throttle Cable/ETC

Switch

" Steering

50 hrs

100 hrs

6 months

12 months

Inspect; lubricate

" Rear Axle

Inspect bearings; lubricate

Inspect; adjust and lubricate if needed

Inspect; lubricate; tighten fasteners

Inspect; tighten fasteners

Inspect; clean

" Drive Chain

" Front Suspension

" Rear Suspension

J Clutches (drive and

driven)

Engine Mounts

100 hrs

12 months

Inspect

128

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Maintenance

Periodic Maintenance Schedule

Item to Inspect

Hours/

Miles

Frequency Remarks

Spark Plug

100 hrs

12 months

Inspect; replace if necessary

Inspect; adjust as needed

J Ignition Timing

J Fuel System

Check for leaks at tank cap, lines, fuel

valve, filter, pump and carburetor. Replace

lines every two years.

J Fuel Filter

100 hrs

12 months

36 months

As needed

Replace annually

Inspect; replace if necessary

Adjust

J Front wheel bearings 300 hrs

J Idle Speed

As needed

J Toe adjustment

Inspect periodically adjust when parts are

replaced

129

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Maintenance

Lubrication Recommendations

Item

Lube

Method

Fill oil tank.

Frequency

1. Engine Oil

Polaris VES II

Synthetic 2-cycle

As needed and

when refueling

2. Gearcase Oil

Level

AGL Synthetic

gearcase lube

See Page 150.

Change annually or at

100 hrs. Maintain in

SAFE range.

3. Drive Chain

4. Front A-Arm

Polaris chain lube

or SAE 80/90

Lubricate as required As required

and before each ride

in wet conditions.

" L Grease

Locate fittings and

grease.

Every 3 months or 50

hrs.

Grease more often under severe use, such as wet or dusty conditions.

L Use Polaris Premium all Season Grease or grease conforming to NLGI No. 2.

130

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Maintenance

Lubrication Recommendations

90cc Models

50cc Models

131

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Maintenance

Lubrication Recommendations

Polaris 2-Cycle Lubricants

Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically

designed for today’s 2-cycle engines. These oils provide additives for 2-cycle engines that

are lacking in today’s fuel. These additives keep ring grooves cleaner for less ring sticking

and improved overall engine cleanliness. We recommend the use of these oils for all

Polaris 2-cycle engines.

Polaris premium 2-cycle oils will mix with each other, but we recommend that you choose

only one of the oils and use it exclusively through the life of the unit. Never mix Polaris

2-cycle oils with any other brand of oil, including Polaris Nature Oil Biodegradable oil.

Their incompatibility could result in engine damage. See page 170 for the part numbers of

Polaris products.

132

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Maintenance

Lubrication Recommendations

Polaris VES II Synthetic 2-Cycle Oil

Your ATV has been primed with VES II synthetic oil. We recommend the continued use of

this oil. It’s been formulated for low smoke, low odor, low deposits and high lubricity.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil or Premium Gold Synthetic Oil suitable for use.

133

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Maintenance

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

First 5 hrs.

25 hrs.

50 hrs.

75 hrs.

100 hrs.

134

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Maintenance

Interval

Performed

Servicing

Date

Servicing

Dealer

or Person

Remarks

135

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Maintenance

Rear Spring Adjustment

The rear shock absorber spring is adjusted by rotating the

adjuster (A) in the direction required to increase or

decrease spring tension.

Handlebar Adjustment

WARNING

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.

136

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Maintenance

Handlebar Adjustment

The handlebars can be adjusted for rider

preference.

1. Remove the pod to access the handlebar bolts.

2. Loosen the four bolts (A).

3. Adjust the handlebar to the desired height. Be

sure the handlebars do not hit the gas tank or

any other part of the machine when turned

fully to the left or right.

4. Lightly tighten each bolt equally to prevent

uneven gaps in the block.

5. Torque the handlebar adjuster block bolts to

7.3 ft. lbs.

137

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Maintenance

Axle and Wheel Nut Torque Specifications

Check the following nuts occasionally and when they’ve been loosened for maintenance.

Specification

Front Spindle Nuts

Rear Spindle Nuts

42-45 ft. lbs. (57-61 Nm)

78-81 ft. lbs. (106-110 Nm)

NOTE: All nuts with a cotter pin installed must be serviced by an authorized Polaris

dealer.

Front 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.

138

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Maintenance

Speed Control Systems

Per ANSI / SVIA--1--2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed

of youth models is restricted to under 10 MPH for the 50 cc models and under 15 MPH for

the 90 cc models.

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.

Polaris Youth ATVs have an electronic speed control system and an adjustable throttle

limiting screw. These speed limiting devices may be adjusted/removed only by consumers

when they determine that their child is capable of handling the additional speed.

Per ANSI / SVIA--1--2001 (sec. 6.2) the unrestricted top speed is less than 15 MPH for the

50 cc models and less than 30 MPH for the 90 cc models.

139

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Maintenance

Speed Control Systems

Electronic Speed Control System

Your Polaris ATV has a speed control system

that controls engine RPM and speed of the ATV.

Adjust speed by removing or installing the

jumper on the CDI (A). With the jumper

installed, 50cc models will travel no faster than

10 mph and 90cc models will travel no faster than

15 mph. With the jumper removed, 50cc models

will travel no faster than 15 mph and 90cc models will

travel no faster than 30 mph.

50cc

90cc

Jumper Removal and Installation

1. Remove the CDI and its rubber mounting strap from the mounting tab located on the

frame bulkhead near the steering post. It can be accessed through the left (90cc

models) or right (50cc models) front fender.

2. Remove the two screws (B) from the jumper to remove or install the jumper, then

reinstall the screws.

3. Reinstall the CDI and mounting strap onto the mounting tab.

140

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Maintenance

Speed Control Systems

Throttle Stop Speed Control System

Adjusting speed at the CDI is the recommended

method of speed control, but the throttle stop system

may also be used. Use the following procedure to

control how far the throttle opens.

1. Loosen the jam nut (A)

2. Turn the screw (B) inward to reduce speed or

outward to increase speed.

3. Tighten the jam nut after adjusting.

141

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Maintenance

Steering Inspection

The steering assembly of the ATV should be checked periodically for loose nuts and bolts.

If any are found, have your dealer tighten them before operating the ATV.

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not

attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an

authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended

toe alignment is 1/8” to 1/4” toe out.

1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used

as an indicator of whether the handlebars are straight. The frog should always point

straight back from the steering post.

2. Place stands (A) in front of the vehicle, perpendicular to the rear tires. See illustration.

142

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Maintenance

Toe Alignment

3. Tie an elastic string around the stands, making

sure the string just touches the side surface of the

rear tires on each side of the vehicle and goes

around the stands in front of the vehicle (2).

4. Measure the distance from the string to the rim at

the front and rear of the front rim (3). Rear

measurement should be 1/16″ - 1/8″ (.2 to .3 cm)

more than the front measurement.

NOTE: If you discover improper alignment, see

your Polaris dealer for service.

Camber and Caster

The camber and caster are non-adjustable.

143

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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 ″ (1.5mm - 3.2mm) (A). If adjustment is

required, turn the adjustment nut (B) until the

freeplay falls in to the acceptable limit.

Brake Freeplay

Brake Freeplay Specifications

Model

Predator 50

Front

Rear

.1″ - .39 ″ (2.5-9.9 mm)

.40″ - .80″ (10-20 mm)

.15″ - .30″ (3.8-7.6 mm)

.40″ - .80″ (10-20 mm)

Predator 90

Sportsman 90

144

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Maintenance

Brake Adjustment

Periodically check (measure) the freeplay of the front and

rear brakes (A). Refer to the specifications chart on page

144 for the acceptable range of freeplay.

To adjust the front brake freeplay, turn the adjustment

knob (B). To adjust the rear brake freeplay, turn the

adjuster nut (C).

Brake Lever Travel

Service the brakes when brake lever travel (D) reaches the

following total lever travel measurements. Always service

the brakes when there is no longer sufficient stopping

ability at the specified lever travel setting.

Component

Front brake lever

Rear brake lever

Total Lever Travel

1 3/4” (45mm)

2 1/2” (65mm)

145

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Maintenance

Air Cleaner

Inspect the air filter weekly or after every 50

hours of operation. If the ATV is ridden in

wet or dusty conditions, clean the filter

more often.

1. Remove the screws (A) on the airbox

and remove 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.

CAUTION

Never operate the ATV with the filter element removed. Dirt will enter the engine

causing serious rapid wear and damage to the engine.

146

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Maintenance

Carburetor Adjustments

Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging

from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or

higher.

Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine

loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.

Although this power cannot be regained, adjustments to the carburetor and drive system can

be made to allow more efficient operation.

Optional jets, available from your Polaris dealer, are required for operation above 6,000 feet

and temperatures below +40 degrees F. (4 degrees C.) NOTE: Continuous operation of

the engine without proper jetting when required can cause poor performance, overheating or

engine damage. See your Polaris dealer for more information about jetting the ATV for

conditions in your area.

147

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Maintenance

Spark Plugs

S Use NGK BP7HS or NGK BPR7HS spark plugs.

S Proper electrode gap is .24”-.28” (0.6-0.7 mm).

S Spark plug torque is 14 ft. lbs. (19 Nm).

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. Immediately check the spark plug for correct color.

CAUTION

Using non-recommended spark plugs can result in serious engine damage.

Always use Polaris-recommended spark plugs.

WARNING

A hot exhaust system and engine can cause serious burns. Wear protective gloves

when removing a spark plug for inspection.

148

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Maintenance

Spark Plugs

NORMAL: 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. NOTE: The tip should not be white. A

white insulator tip indicates overheating, caused by use of an improper spark plug or

incorrect carburetion adjustments.

WET FOULED: The wet fouled 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 of fouling are excessive oil, use of non-recommended oil, improper

use of the choke, or incorrect carburetion adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the spark plug

counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 14 ft. lbs. (19 Nm).

149

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Maintenance

Cylinder Head/Cylinder Base Fastener Torque

Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque

at the first service or after 25 hours.

Gearcase Lubrication

The gearcase fill plug (A) is located on the top

of the gearcase. The sight glass (B) is on the

righthand side of the gearcase. The oil level

must be maintained in the safe zone of the sight

glass. It should be checked monthly and

changed annually.

With the ATV on a level surface, check the oil

level through the sight glass. If the level is low,

add AGL Synthetic Gearcase Lubricant. See

page 170 for the part numbers of Polaris

products.

150

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Maintenance

Gearcase Oil Change

1. Remove the fill plug.

2. Remove the gearcase drain plug and drain the oil into a drain pan. Dispose of properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add AGL Synthetic Gearcase Lubricant (about 7 oz.) to the safe zone in the sight glass.

5. Replace the fill plug and check for leaks.

151

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Maintenance

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.

Maintain proper tire pressure as described on the decal on your ATV and in the

owner’s manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.

152

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Maintenance

Tire Tread Depth

Always replace tires when tread depth is worn to

1/8″ (.3 cm) or less. See illustration.

1/8I (.3 cm)

Wheel Removal

1. Stop the engine and lock the parking brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a

suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

153

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Maintenance

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. Install the wheel bolts (A) and finger

tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the bolts to 22 ft. lbs.

(30 Nm).

154

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Maintenance

Drive Chain Inspection and Adjustment

Regularly lubricate the drive chain with Polaris chain spray lube or an approved chain lube.

See page 170 for the part numbers of Polaris products.

CAUTION

Washing the drive chain with a high pressure washer or gasoline can cause

premature wear and drive chain failure. Don’t use a high pressure washer or

gasoline to clean the drive chain.

CAUTION

Adjusting or operating the ATV with improper rear drive chain slack can result in

severe damage to the transmission and drive components. Always make sure the

slack is within the stated specifications.

155

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Maintenance

Drive Chain Inspection and Adjustment (90cc Models)

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. Fasten the

strap (A) around the axle and rear bumper tube.

3. Tighten the strap until a straight

line (B) can be drawn from the rear

axle to the gearcase output shaft

intersecting the swing arm pivot.

This establishes the tightest chain

position.

4. Pull down on the chain tensioner (C)

to move it out of the way, then

measure chain slack. It should have

1/4”-1/2” (6-12 mm) deflection.

5. If the chain needs adjustment, use the

procedure on page 158.

156

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Maintenance

Drive Chain Inspection and Adjustment (50cc Models)

1. Check the amount of chain

slack by moving the vehicle

slightly forward to gain slack

at the top side of the chain.

2. The chain should have

1/4”-1/2” (6-12 mm)

deflection. If the chain needs

adjustment, use the procedure

on page 158.

157

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Maintenance

Drive Chain Slack Adjustment

CAUTION

Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud.

1. Loosen the four rear housing mount

bolts (A).

2. Loosen the chain adjuster lock nut.

3. Turn the chain adjuster (B) clockwise to

1/4”-1/2” (6-12 mm) deflection.

4. Tighten the chain adjuster lock nut to

84 in. lbs. (9.4 Nm).

5. Tighten the four rear housing mount

bolts to 43 ft. lbs. (60 Nm).

158

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Maintenance

Brakelight Lamp Replacement

If the brakelight doesn’t work, the lamp may need to be replaced.

1. From the rear of the brakelight, remove the two

screws (A) holding the lens cover in place and

remove the lens cover (B).

2. Remove the lamp (C) and replace it with a new

recommended lamp.

3. Test the brakelight to ensure operation.

4. Reinstall the lens cover.

159

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Maintenance

Cleaning and Storage

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 the ATV

The best and safest way to clean your ATV is with a garden hose and a pail of mild soap

and water. 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 and safety labels are damaged, contact your a Polaris dealer for

free replacement.

Polaris does not recommend the use of a high pressure type car wash system for washing

the ATV. If a high pressure system is used, exercise extreme care to avoid water damage to

the wheel bearings, transmission seals, body panels, brakes and warning labels.

NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for

a while to evaporate any water that may have entered the engine or exhaust system.

160

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Maintenance

Cleaning and Storage

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of

harsh cleaners since they can scratch the body finish.

CAUTION

Certain products, including insect repellants and chemicals, will damage plastic

surfaces. Use caution when using these products near plastic surfaces.

161

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Maintenance

Cleaning and Storage

Storing the ATV

Proper preparation of the engine and fuel system is vital to the prevention of rust and

corrosion on engine parts. Whenever the machine is stored for a period of more than 60

days, the engine must be fogged. Use Polaris fogging oil and follow the directions on the

can.

Always add a fuel conditioner/stabilizer to the fuel tank before storage. Run the engine for

five minutes to get the additives through the entire fuel system and then top off with fuel.

Fuel additive products are available through your Polaris dealer.

NOTE: Jet restriction caused by improper storage can cause lean conditions and very poor

slow speed driving quality.

162

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Maintenance

Cleaning and Storage

Transporting the ATV

Follow these procedures when transporting the ATV.

1. Turn the fuel valve off.

2. Be sure the fuel cap, oil cap and seat are installed correctly and securely.

3. Tie the frame of the ATV to the transporting unit securely using suitable straps or rope.

4. Lock the parking brake.

Accessories

Polaris has a wide range of accessories available for your ATV. See your Polaris dealer.

163

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Specifications

Predator 50

Rider Capacity/Maximum Weight

Displacement

Carburetion

1 Rider/90 lbs. (41 kg)

49cc

H68K

Cooling

Air Cooled

Engine type

2-Stroke

Lubrication

Oil Injected

Oil Capacity

20 oz. (.6 liter)

Fuel Capacity

Starting

Drive System

Final Drive

1 gallon (3.8 liters)

Electric with kick-start backup

Automatic CVT

Chain

Front Suspension

Rear Suspension

Single control arm with 3″ (7.6 cm) of travel

Spring over shock with 3″ (7.6 cm) of travel

164

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Specifications

Predator 50

Drum

Mechanical Lock

16 x 8 - 7 (3 psi)

60″ (152 cm)

Front/Rear Brakes

Parking Brake

Front Tires

Rear Tires

Turning Radius (inside tire)

Wheel Base

33″ (84 cm)

Ground Clearance

Dry Weight

4″ (10 cm)

185 lbs. (84 kg)

Length/Width/Height

Brake Light

Low Oil Light

48″ (10 cm) / 31.5″ (122 cm) / 28″ (71 cm)

Standard

165

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Specifications

Predator 90

Rider Capacity/Maximum Weight

Displacement

Carburetion

1 Rider/150 lbs. (68 kg)

89cc

H68K

Cooling

Fan Cooled

Engine type

2-Stroke

Lubrication

Oil Injected

Oil Capacity

1.1 quarts (1 liter)

Fuel Capacity

Starting

Drive System

Final Drive

1.3 gallons (5 liters)

Electric with kick-start backup

Automatic CVT

Chain

Front Suspension

Rear Suspension

A-arm with 4.25″ (10.8 cm) travel

Spring over shock with 4.25″ (10.8 cm) of travel

166

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Specifications

Predator 90

Drum

Mechanical Lock

19 x 7 - 8 (3 psi)

18 x 9.5 - 8 (3 psi)

76″ (193 cm)

Front/Rear Brakes

Parking Brake

Front Tires

Rear Tires

Turning Radius (inside tire)

Wheel Base

38.5″ (98 cm)

Ground Clearance

Dry Weight

5″ (12.7 cm)

230 lbs. (104 kg)

Length/Width/Height

Brake Light

Low Oil Light

57″ (145 cm) / 35.75″ (91 cm) / 36.1″ (91.8 cm)

Standard

167

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Specifications

Sportsman 90

Rider Capacity/Maximum Weight

Displacement

Carburetion

1 Rider/150 lbs. (68 kg)

89cc

H68K

Cooling

Fan Cooled

Engine type

2-Stroke

Lubrication

Oil Injected

Oil Capacity

Fuel Capacity

Starting

Drive System

Final Drive

1.1 quarts (1 liters)

1.32 gallons (5 liters)

Electric with kick-start backup

Automatic CVT

Chain

Front Suspension

Rear Suspension

A-arm with 4.25″ (10.8 cm) of travel

Spring over shock with 4.25″ (10.8 cm) of travel

168

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Specifications

Sportsman 90

10 lbs. (4.5 kg)

20 lbs. (9 kg)

Drum

Front Rack Capacity

Rear Rack Capacity

Front/Rear Brakes

Parking Brake

Front Tires

Rear Tires

Mechanical Lock

19 x 7 - 8 (3 psi)

19 x 9.5 - 8 (3 psi)

38.5″ (98 cm)

5″ (12.7 cm)

Wheel Base

Ground Clearance

Turning Radius (inside tire)

Dry Weight

76″ (193 cm)

238 lbs. (108 kg)

Length/Width/Height

Brake Light

Low Oil Light

59.75″ (151.8 cm) / 35.75″ (90.8 cm) / 36.6″ (93 cm)

Standard

169

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Polaris Products

Part No.

Description

Engine Lubricant

2870791

2874438

2871721

2871098

Fogging Oil (12 oz. Aerosol)

VES II Synthetic 2-Cycle Oil (qt.)

Premium Gold Synthetic 2-Cycle Oil (qt.)

Premium 2-Cycle Engine Oil (qt.)

Gearcase / Transmission Lubricants

AGL Synthetic Gearcase Lubricant (qt.)

Angle Drive Fluid (8 oz.)

2873602

2871653

2871654

Premium Drive Hub Fluid (8 oz.)

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

170

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Polaris Products

Part No.

Description

Grease / Specialized Lubricants

Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease (2 oz.)

2871312

2871322

2871423

2871460

2871515

2871551

2871329

2872073

2872348

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Dielectric Grease (Nyogelt)

Chain Lube, Aerosol (6.25 oz.)

Chain Lube, Aerosol (16 oz.)

Additives / Miscellaneous

2871326

2870652

2870990

2872893

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid (12 oz.)

Engine Degreaser (12 oz.)

171

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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 fuel valve to reserve, refuel

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Clogged fuel valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Crankcase filled with water or fuel

Clogged fuel filter

Replace with new fuel

Inspect plug(s), replace if necessary

Inspect plug(s), verify stop switch is on

Immediately see your Polaris dealer

Replace the filter

Low battery voltage

Recharge battery with .5 amp charger

See your Polaris dealer

Mechanical failure

172

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Troubleshooting

Engine Doesn’t Turn Over

Possible Cause

Solution

Low battery voltage

Recharge battery with .5 amp charger

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

173

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Troubleshooting

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

174

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery with .5 amp charger

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

175

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Troubleshooting

Engine Runs Irregularly, Stalls or Misfires

Possible Lean Fuel Mixture Cause

Low or contaminated fuel

Low octane fuel

Solution

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect jetting

See your Polaris dealer

Possible Rich Fuel Mixture Cause

Overuse of choke

Solution

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your Polaris dealer

Fuel is very high octane

Incorrect jetting

176

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Troubleshooting

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Turn fuel valve to reserve, refuel

Inspect and replace

Kinked or plugged fuel vent line

Water present in fuel

Replace with new fuel

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery with .5 amp charger

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

177

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Warranty

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH 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 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. This warranty

begins on the date of purchase. This warranty is transferrable to another consumer during the warranty period

through a Polaris dealer.

REGISTRATION

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 PUR-

CHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN

ORDER TO HAVE VALID WARRANTY ON THE ATV. No verification of registration will be sent to the pur-

chaser as the copy of the Warranty Registration Form will be the warranty entitlement. If you have not signed the

original registration and received the “customer copy”, please contact your dealer immediately. NO WARRANTY

COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.

Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation. Purchas-

ing a machine in the crate or without proper dealer set--up will void your warranty coverage.

178

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Warranty

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 warran-

ty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained,

used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur

during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this war-

ranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material,

corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond Polaris’

control.

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 replace-

ment of any defective materials, or components or products. THE REMEDIES SET FORTH IN THIS WAR-

RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSE-

QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS

OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some

states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so

the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

179

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Warranty

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

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

implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

180

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Warranty

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). Polaris

suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform

warranty service.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance

they will contact the appropriate personnel at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

Recommended Lubricants

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of Polaris

engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered by warranty.

181

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Warranty

EXPORTED VEHICLES

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-

LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING

DEALER’S AUTHORIZED LOCATION.

This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers

may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warran-

ty or service bulletin coverage if you have any questions.

This policy does not apply to vehicles registered to government officials or military personnel on assignment out-

side the country of the selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

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 traveling

within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from

any authorized Polaris dealer who sells the same line as your vehicle.

Outside the country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased, you should take your ve-

hicle to an authorized Polaris dealer. You must show the dealer photo identification from the country of the selling

dealer’s authorized location as proof of residence. Upon residence verification, the servicing dealer will be autho-

rized to perform the warranty repair.

182

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Warranty

EXPORTED VEHICLES

How to Get Service

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the

destination country before you move. Vehicles importation rules vary considerably from country to country. You

may be required to present documentation of your move to Polaris Industries in order to continue your warranty

coverage. You may also be required to obtain documentation from Polaris Industries in order to register your ve-

hicle in your new country.

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 originally

purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have not followed the proce-

dure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.

(Vehicles registered to Government officials or military personnel on assignment outside of the country where the

vehicle was purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-763-417-8650

Canada: 1-204-925-7100

183

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Index

Air Cleaner . . . . . . . . . . . . . . . . . . . 146

Axle and Wheel Nut

Daily Pre-Ride Inspection . . . . . . . 94-95

Drive Chain Adjustment . . . . . . 155-157

Driver Warnings . . . . . . . . . . . . . . 47-73

Driving Across Hillsides . . . . . . . . . 106

Driving Downhill . . . . . . . . . . . . . . 110

Driving on Slippery Surfaces . . . . . 102

Driving Over Obstacles . . . . . . . . . . 114

Driving Procedure . . . . . . . . . . . . . 100

Driving Safely . . . . . . . . . . . . . . 98-114

Driving Through Water . . . . . . . . . . 112

Driving Uphill . . . . . . . . . . . . . . . . 104

Gas Cap . . . . . . . . . . . . . . . . . . . 21, 87

Gearcase Lubrication . . . . . . . . . . . 150

Gearcase Oil Change . . . . . . . . . . . . 151

Torque Specifications . . . . . . 138

Battery . . . . . . . . . . . . . . . . . . . 122-124

Battery Installation . . . . . . . . . . . . . 124

Battery Removal . . . . . . . . . . . . . . . 123

Battery Storage . . . . . . . . . . . . . . . . 124

Brake Adjustment . . . . . . . . . . . . . . 145

Brake Freeplay . . . . . . . . . . . . . . . . 144

Brake Freeplay Specifications . . . . . 144

Brake Lever Travel . . . . . . . . . . . . . 145

Brake Levers . . . . . . . . . . . . . . . . . . . 22

Brakelight Lamp Replacement . . . . 159

Brakes . . . . . . . . . . . . . . . . . . . . . . 82-84

Break-in Period . . . . . . . . . . . . . . . 92-93

Handlebar Adjustment . . . . . . . . . . 137

Hauling Cargo . . . . . . . . . . . . . . 115-117

Horn Button . . . . . . . . . . . . . . . . 19, 78

Ignition Switch . . . . . . . . . . . . . . . . . 23

Electronic Speed Control System . . 140

Emission Control Systems . . . . . . . 119

Engine Start Button . . . . . . . . . . . . . . 79

Engine Stop Switch . . . . . . . . . . . . . . 78

Equipment Modifications . . . . . . . . . 16

K-turn . . . . . . . . . . . . . . . . . . . . . . . 108

Kick Start . . . . . . . . . . . . . . . . . . . . . 20

Kick-Start Lever . . . . . . . . . . . . . . . . 90

Know Your ATV . . . . . . . . . . . . . . 18-24

Camber and Caster . . . . . . . . . . . . . 143

Carburetor Adjustments . . . . . . . . . 147

Chain Adjustment . . . . . . . . . . . . . . 158

Choke Lever . . . . . . . . . . . . . . . . . . . 78

Cleaning and Storage . . . . . . . . 160-163

Controls . . . . . . . . . . . . . . . . . . . . 77-91

Cylinder Head Torque . . . . . . . . . . . 150

Lights . . . . . . . . . . . . . . . . . . . . . . . . 85

Lubricants, 2-Cycle . . . . . . . . . . . . . 132

Lubrication Recommendations . 130-133

Features . . . . . . . . . . . . . . . . . . . . 77-91

Footwell Riser . . . . . . . . . . . . . . . . . . 91

Front Wheel Hub Tightening . . . . . 138

Fuel Filter . . . . . . . . . . . . . . . . . . . . . 88

Fuel System . . . . . . . . . . . . . . . . . 86-88

Fuel Valve . . . . . . . . . . . . . . . . . . . . . 88

184

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Index

Main Switch . . . . . . . . . . . . . . . . . . . 77

Maintenance . . . . . . . . . . . . . . . 120-163

Maintenance Chart Key . . . . . . . . . 126

Maintenance Record . . . . . . . . . . . . 134

Maintenance Schedule . . . . . . . 125-129

Making Turns . . . . . . . . . . . . . . . . . 101

Rear Spring Adjustment . . . . . . . . . 136

Recommended Lubricants . . . . . . . 181

Riding Rules . . . . . . . . . . . . . . . . . 28-31

Table of Contents . . . . . . . . . . . . . . . .

Tether Strap . . . . . . . . . . . . . . . . . . . 23

Throttle . . . . . . . . . . . . . . . . . . 19, 80-81

Throttle Cable Adjustment . . . . . . . 144

Throttle Stop Speed Control System 141

Tires . . . . . . . . . . . . . . . . . . . . . . . . 153

Toe Alignment . . . . . . . . . . . . . 142-143

Transporting the ATV . . . . . . . . . . . 163

Troubleshooting . . . . . . . . . . . . 172-177

Turning Around on a Hill . . . . . . . . 108

Safety . . . . . . . . . . . . . . . . . . . . . . . 7-16

Safety Decals . . . . . . . . . . . . . . . . 34-45

Safety Training . . . . . . . . . . . . . . . . . .

Seat Latch . . . . . . . . . . . . . . . . . . . . . 21

Signal words . . . . . . . . . . . . . . . . . . . .

Noise Emission Control System . . . 119

Spark Arrestor . . . . . . . . . . . . . . . . 119

Spark Plug Removal . . . . . . . . . . . . 149

Spark Plug Replacement . . . . . . . . . 149

Spark Plugs . . . . . . . . . . . . . . . . 148-149

Specifications . . . . . . . . . . . . . . 164-169

Speed Control Systems . . . . . . . 139-141

Start Button . . . . . . . . . . . . . . . . . . . . 79

Starting the Engine . . . . . . . . . . . . 96-97

Steering Inspection . . . . . . . . . . . . . 142

Stop Switch . . . . . . . . . . . . . . . . . 19, 78

Storing the ATV . . . . . . . . . . . . . . . 162

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Oil System . . . . . . . . . . . . . . . . . . . . 89

Oil tank . . . . . . . . . . . . . . . . . . . . . . . 89

Understanding Warnings . . . . . . . . . . 32

Vehicle Identification Numbers . . 74-75

Parking Brake . . . . . . . . . . . . . . . . . . 83

Parking Brake . . . . . . . . . . . . . . . . . 84

Parking on a Hill or Incline . . . . . . . . 111

Polaris Products . . . . . . . . . . . . 170-171

Pre-Ride Check . . . . . . . . . . . . . . . 25-27

PVT System . . . . . . . . . . . . . . . 120-121

Warnings . . . . . . . . . . . . . . . . . . . . . . .

Warranty . . . . . . . . . . . . . . . . . . 178-183

Washing the ATV . . . . . . . . . . . . . . 160

Waxing the ATV . . . . . . . . . . . . . . . 161

Symbols . . . . . . . . . . . . . . . . . . . . . . .

Welcome . . . . . . . . . . . . . . . . . . . . . . .

Wheel Installation . . . . . . . . . . . . . . 154

Wheel Removal . . . . . . . . . . . . . . . 153

185

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