Polaris Motorcycle Scrambler 90 User Manual
2001 YOUTH ATV MODELS  
Owner’s Safety and Maintenance Manual  
Read this manual carefully. It contains important safety information.  
Scrambler 50 - No one under the age of 6 should ride this vehicle.  
Sportsman 90 and Scrambler 90 - No one under the age of 12 should ride these vehicles.  
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Indicates a potential hazard which could  
result in severe injury or death.  
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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 - passen-  
gers affect balance and steering and increaqse 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 handingl and control.  
Improper ATV use can result in SEVERE INJURY or DEATH  
Part No. 9916424  
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FOREWORD  
Congratulations and thank you from Polaris Industries Inc. for purchasing one of our  
all-terrain vehicles (ATVs). Built with American engineering and manufacturing know-  
how, it is designed to provide superior riding comfort, enjoyment, and safety.  
This manual is furnished to ensure that the operator and parents are aware of safe  
operating procedures. It also includes information about the general care and main-  
tenance of your ATV.  
Carefully read the following pages. If you have any questions regarding this ATV con-  
tact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge  
and facilities to provide you with the best service possible.  
i
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PROTECT YOUR SPORT  
Know all local, state/province riding laws;  
Respect your vehicle;  
Respect the environment; and  
You will gain the respect of others.  
We also advise you to strictly follow the recommended maintenance program as out-  
lined. This preventive maintenance program is designed to ensure that all critical  
components on this ATV are thoroughly inspected at various intervals.  
All information in this manual is based upon the latest product data and specifications  
available at the time of printing. Polaris Industries Inc. reserves the right to make  
product changes and improvements which may affect illustrations or explanations.  
No part of this manual shall be reproduced or used without the written permission of  
Polaris Industries Inc.  
Illustrations included in this manual are general representations of parts  
having a similar function. Your model may differ.  
ii  
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INTRODUCTORY SAFETY MESSAGE TO PARENTS  
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles  
differently from other vehicles including motorcycles and cars. A collision or rollover  
can occur quickly, even during routine maneuvers such as turning and driving on hills  
or over obstacles, if you fail to take proper precautions.  
Children differ in skills, physical abilities, and judgement. Some children may not be  
able to operate an ATV safely. Parents should supervise their child’s use of the ATV  
at all times. Parents should permit continued use only if they determine that the child  
has the ability and maturity to operate the ATV safely.  
ailure to follow the warnings contained in this manual can result in  
SERIOUS INJURY or DEATH.  
• Read this manual and all labels carefully and follow the operating procedures de-  
scribed.  
• 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.  
iii  
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• Always follow the age guidelines for your machine. Youth ATVs are designed and  
intended for use by children in two age groups. The Scrambler 50 is for children  
not less than 6 years of age. The Scrambler 90 and the Sportsman 90 are for chil-  
dren not less than 12 years of age. No children under the age of 16 should ride an  
ATV designed and sold for an adult.  
• 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.  
• Always avoid operating an ATV on any paved surfaces, including sidewalks, drive-  
ways, parking lots and streets.  
• Never operate an ATV on any public street, road or highway, even a dirt or gravel  
one.  
• 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.  
• Never consume alcohol or drugs before or while operating this ATV.  
• Never operate at excessive speeds. Always travel at a speed which is proper for  
the terrain, visibility and operating conditions, and your experience.  
iv  
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• Never attempt wheelies, jumps or other stunts.  
• Always inspect your ATV each time you use it to make sure it is in safe operating  
condition. Always follow the inspection and maintenance procedures and sched-  
ules described in this manual.  
• Always keep both hands on the handlebars and both feet on the footrests of the  
ATV during operation.  
• Always go slowly and be extra careful when operating on unfamiliar terrain. Always  
be alert to changing terrain conditions when operating the ATV.  
• Never operate on excessively rough, slippery or loose terrain.  
• Always follow proper procedures for turning as described in this manual. Practice  
turning at low speeds before attempting to turn at faster speeds. Do not turn at ex-  
cessive speed.  
• Always have the ATV checked by an authorized Polaris dealerif it has been involved  
in an accident.  
• Never operate the ATV on hills too steep for the ATV or for your abilities. Practice  
on smaller hills before attempting larger hills.  
v
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• Always follow proper procedures for climbing hills as described in this manual.  
Check the terrain carefully before you start up any hill. Never climb hills with exces-  
sively slippery or loose surfaces. Shift your weight forward. Never open the throttle  
suddenly or make sudden gear changes. Never go over the top of any hill at high  
speed.  
• 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.  
• Always follow proper procedures for crossing the side of a hill as described in this  
manual. 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.  
vi  
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• Always use proper procedures if you stall or roll backwards when climbing a hill.  
To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll  
backwards, follow the special procedure for braking described in this manual. Dis-  
mount on the uphill side or to either side if pointed straight uphill. Turn the ATV  
around and remount, following the procedure described in this manual.  
• Always check for obstacles before operating in a new area. Never attempt to oper-  
ate over large obstacles, such as large rocks or fallen trees. Always follow proper  
procedures when operating over obstacles as described in this manual.  
• 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 con-  
trol.  
• Avoid operating the ATV through deep or fast flowing water. If you cannot avoid  
water which exceeds the recommended maximum depth (pg. 98), go slowly, bal-  
ance your weight carefully avoiding sudden movements, maintain a slow and  
steady forward motion, do not make sudden turns or stops, and do not make sud-  
den throttle changes.  
• 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.  
vii  
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• Always use the size and type tires specified in this manual. Always maintain proper  
tire pressure as described in this manual.  
• Never modify an ATV through improper installation or use of accessories.  
• Never exceed the stated load capacity for an ATV. Cargo should be properly distrib-  
uted and securely attached. Reduce speed and follow instructions in this manual  
for carrying cargo or pulling a trailer. Allow greater distance for braking.  
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safe-  
ty Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.  
Additional Important Information...  
Due to our concern for the safety of our customers and the general public, Polaris  
hereby strongly recommends and requests that consumers not have installed on a  
Polaris ATV any equipment which is intended to increase the speed or power of the  
vehicle; or make any other modifications to the vehicle for these purposes. Any modi-  
fications to the original equipment of the ATV substantially increase the risk of bodily  
injury. Please be aware that these modifications may create a substantial safety haz-  
ard.  
viii  
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Polaris hereby informs you that the warranty on your ATV is terminated if any such  
equipment has been added to the ATV or any modifications have been made to the  
ATV which increase its speed or power.  
We also advise you to strictly followthe recommended maintenance programoutlined  
in this manual. This preventive maintenance program is designed to ensure that all  
critical components on the ATV are thoroughly inspected by your dealer at various  
mileage intervals.  
NOTE:  
The addition of certain accessories may change the handling characteristics of the  
ATV.  
Be certain any accessories added to this ATV have been approved by Polaris.  
Familiarize yourself with their function and affect on the ATV.  
Indicates a potential hazard which could  
result in severe injury or death.  
ix  
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TABLE OF CONTENTS  
RIDER’S SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R-1 - R-20  
UNDERSTANDING WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4  
GENERAL SAFETY AND DESCRIPTION OF LABELS . . . . . . . . . . . . . . . . . . . . . 5-18  
DAILY PRE-RIDE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21  
OPERATION WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-46  
VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47-48  
CONTROL AND PARTS FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-69  
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-71  
RIDING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-73  
VEHICLE BREAK IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-76  
CARRYING LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-80  
DAILY PRE-RIDE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81-83  
RIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-103  
x
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TABLE OF CONTENTS  
PVT SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104-105  
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-111  
NOISE EMISSION CONTROL SYSTEM REGULATION . . . . . . . . . . . . . . . 112-114  
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115-161  
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162-168  
WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169-170  
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171-172  
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173-178  
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179-180  
xi  
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RIDER’S SECTION  
R--1  
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KNOW YOUR MACHINE  
PARENTS: Review the information in this manual with any child who may be  
operating the ATV. It is up to you to teach your child the proper and safe way  
to ride an ATV. You must set boundaries and adhere to them, keeping your  
child’s safety foremost in your mind. Never allow your child to operate this  
machine without adult supervision.  
CHILDREN: Before you ride your new Polaris ATV, there are some important  
things you should know. How to keep safe is the most important thing. You  
must also learn some things that will keep you and those around you safe while  
you are riding.  
R--2  
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KNOW YOUR MACHINE  
Pay attention when you see this symbol.:  
This is the safety alert symbol. When you see this symbol on your  
machine or in this manual it means PAY ATTENTION. If you don’t,  
you could get hurt very badly or even killed. Your safety is involved!  
R--3  
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KNOW YOUR MACHINE  
Before you have an adult start the engine for you for the first time, let’s learn  
about the controls on your new machine.  
1. Engine Stop Switch - When the  
engine is running, you can slide this  
button to the left or the right and the  
engine will stop. The stop switch  
must be in the “middle” position to  
start the engine again.  
2. Throttle Control (A) -This makes your  
OFF  
OFF  
RUN  
ATV go forward when you press it with  
your thumb. You must always make  
sure the throttle control does not stick  
before you operate your ATV. Read  
more about it on page R--12.  
1
A
2
R--4  
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KNOW YOUR MACHINE  
3. Kick Starter (B) - If your battery is too  
weak to start your machine, you can  
push on this with your foot to start the  
engine. Have an adult show you how  
this works. There is more information  
on how to use the kickstart on page  
69.  
B
3
R--5  
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KNOW YOUR MACHINE  
4. Gas Cap - This is where the gas goes  
that will run your ATV. Your ATV will  
not run without gas. Only adults  
should fill the gas tank.  
4
Always have an adult put gas in your machine.  
R--6  
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KNOW YOUR MACHINE  
5. Brake Lever (C) - Squeeze this  
towards the handle bar to make  
your ATV slow down or stop. The  
right hand lever (C-1) controls the  
front brake. The left hand lever  
(C-2) controls the rear brake. To  
slow down or stop, squeeze both  
brake handles at the same time.  
C-2  
C-1  
Always apply both brakes at the  
same time or loss of vehicle con-  
trol can occur resulting in serious  
injury or death.  
Always take your thumb off the  
throttle control when you pull the  
brake lever.  
5
R--7  
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KNOW YOUR MACHINE  
6. Ignition Switch - This key must be turned “on” before pushing the starter  
button. You can also use this key to turn off the engine. You can find it on the  
Right-hand side of the Scramblers (D) and on the pod of the Sportsman (E).  
D
E
6
R--8  
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KNOW YOUR MACHINE  
7. Tether Strap/ Switch - This must  
always be attached snugly to your right  
wrist and your machine when you are  
riding. If you fall off your ATV, the tether  
will pull off the switch and the engine  
will stop. Put one end of the tether  
strap around your right wrist. The other  
end must be attached to the ATV.  
Always attach the tether strap before  
you ride. (Sportsman - F and  
F
G
7
Scramblers - G)  
Never ride without the tether strap attached to your right wrist and machine.  
Be careful not to get the cord tangled around the handlebars or any part  
of your body.  
R--9  
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KNOW YOUR MACHINE  
Let’s review the three ways to stop your ATV.  
1. Sliding the shut off switch to the left or right.  
2. Disconnecting the tether strap will shut off the engine.  
3. Turning the key to off will shut off the engine.  
R--10  
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KNOW YOUR MACHINE  
1
R--11  
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PRE RIDE CHECK  
You are almost ready to have an adult start your ATV. Before the ATV is started  
for the first time, you must do a PRE-RIDE CHECK. In fact, every time you ride  
your ATV you must have an adult help you check these things before starting  
it. Let’s learn about these things now.  
ꢀ
Make sure the throttle doesn’t stick. Check this by pushing the 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 open, you have  
a sticky throttle. This means that something is wrong or broken.  
If you have a sticky throttle, do not start the engine. You could get hurt if  
you ride when you have a sticky throttle. Have an adult or your Polaris Deal-  
er fix the throttle.  
R--12  
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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 it go. They should come right back  
to where they were before you squeezed. If they go back slowly or stay on, your  
brakes are sticking.  
If you have sticky brakes, do not start the engine. You could get hurt if you  
ride when you have sticky brakes. Have an adult or your Polaris Dealer fix  
the sticky brakes.  
If you have used the storage area under the seat, make sure the seat is  
ꢀ
locked and in place.  
R--13  
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PRE RIDE CHECK  
Have an adult check the gas level to see if your ATV needs more. Children  
ꢀ
should never add their own gasoline. This should always be done by an  
adult. Before anyone adds gasoline to your ATV they must read the  
instructions and warnings on page 60 in this Owner’s Manual.  
Always have an adult put gas in your machine.  
Have an adult check the engine oil level when the engine is cold. The engine  
ꢀ
is very hot after it has been running. It could burn you. Children should never  
check the oil on their own. An adult should be in charge of keeping the gas and  
oil levels to the full marks.  
R--14  
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PRE RIDE CHECK  
ꢀ
This last check is done with the engine running. You must check to make  
certain that ALL THREE WAYS TO STOP your ATV are working the way they  
should. Do you remember what they are? If you cannot list them, go back to  
page R--10 and review.  
R--15  
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RIDING RULES  
Now you are ready to learn about riding a ATV. You will learn what you can do  
and what you cannot do. The adult with you is your teacher. You must listen  
and pay attention or you won’t be safe when you ride. Remember that safety  
while you ride is the most important thing. Let’s learn how to ride!  
You must always follow the safe riding rules found on the next pages.  
If you do not, you could be hurt really bad or even killed.  
" Your ATV is made for one person. Never carry a passenger. A passenger  
will make the ATV harder to drive. You may lose control and hurt yourself  
and your passenger.  
" Make sure you know where you are going to drive when your ATV is started.  
Make sure the area is safe all around your ATV.  
R--16  
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RIDING RULES  
" Always wear the right kind of clothing when  
you are riding your ATV. You will need a  
good helmet with a face shield or goggles.  
Wear a long sleeved shirt or jacket,  
gloves, long pants, and boots. Make sure  
your clothing fits properly. If it is too small,  
it could keep you from moving easily. If it  
is too big, it could hang down and get  
caught in a moving part.  
L
L
R--17  
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RIDING RULES  
You must always follow the safe riding rules found on the next pages.  
If you do not, you could be hurt really bad or even killed.  
" Never ride alone. An adult should always be watching you in case you need  
help. Always drive within the sight of an adult.  
" Never ride on public trails.  
" Always drive your ATV while sitting down. Keep both hands on the  
handlebars and keep both feet on the running boards.  
R--18  
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RIDING RULES  
" Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise  
that will keep you from hearing cars, trucks or trains that may be coming  
towards you.  
" Don’t ride at night.  
" Learn where there are lakes, rivers, ponds and ditches in your driving area.  
Stay away from them. Never ride on frozen water. You could get hurt or you  
could even die. All ice can be dangerous!  
" Always be alert and pay attention to where you are driving. Pay attention  
to other drivers and be even more careful around them because you don’t  
know what they’re going to do.  
R--19  
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RIDING RULES  
" Never follow another ATV too closely. Always allow lots of time and space  
to stop your ATV.  
" Only ride your ATV where you know it is safe to drive. No driving over the  
flower garden or on the little trees you planted. Be careful of the things  
around you.  
" Always attach the tether strap to your right wrist and machine before riding.  
Respect your ATV;  
respect your environment;  
and you will earn  
the respect of everyone.  
R--20  
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UNDERSTANDING WARNINGS  
ATTENTION:  
Always follow the age guidelines on the machine. YOU MUST MAKE CERTAIN THE  
OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNER’S MANUAL  
BEFORE OPERATION.  
KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!  
It is the parent’s responsibility to teach their children the proper and safe way to ride  
any ATV. This should be done by reading the owner’s manual with your children be-  
fore they first use the ATV and periodically afterwards.  
SAFETY TRAINING  
When you purchased this vehicle your dealer presented a hands-on safety training  
course covering all aspects of ATV safety. In addition, you were provided with certain  
printed material and a video which instructs operators on safe operating procedures.  
1
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UNDERSTANDING WARNINGS  
You should review this information with your child on a regular basis. In the event you  
purchased a used Polaris ATV from a party other than a Polaris dealer, safety training  
can obtained at no charge from any authorized Polaris dealer.  
Failure to follow the warnings contained in this manual can result in severe INJURY  
OR DEATH.  
NOTE: Illustrations used in this manual are for general representation only. Your  
model may differ.  
SAFETY ALERT  
WARNINGS identify special instructions or procedures which, if not correctly  
followed, could result in personal injury, or loss of life. Read all WARNINGS in  
this manual carefully. Always follow their instructions.  
2
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UNDERSTANDING WARNINGS  
The following precautionary signal words are used throughout this manual to convey  
the following messages:  
This is the safety alert symbol. When you see this symbol on  
your machine or in this manual, be alert to the potential for  
personal injury. Your safety is involved!  
Indicates a potential hazard which could  
result in severe injury or death.  
3
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UNDERSTANDING WARNINGS  
The following precautionary signal words are used throughout this manual to convey  
the following messages:  
Indicates a potential hazard which may  
result in minor personal injury or damage  
to the ATV.  
Indicates a situation that can result in damage to the machine.  
The word “NOTE:” in this manual will alert you to key  
information or instructions.  
NOTE  
4
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
NOTE:  
Warning decals have been placed on the vehicle for the protection of the operator(s).  
Read and follow the instructions on each decal carefully. In the event any decal be-  
comes illegible or comes off, contact your Polaris dealer for a replacement. Any safe-  
ty decal needing replacement will be provided by Polaris at no charge. The part num-  
ber is printed on the decal.  
5
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
WARNING  
1
6
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
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 DEAL-  
ER FOR A REPLACEMENT.  
7
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
2
2
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
S
S
S
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.  
S
Never operate this ATV on HILLS steeper than 15 degrees  
15°. To prevent flipover on hilly terrain, use throttle  
and brakes gradually.  
(Found on Scrambler 50)  
8
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SAFETY WARNING AND OPERATION DECALS  
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.  
9
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SAFETY WARNING AND OPERATION DECALS  
2
2
S
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.  
Adult supervision is required.  
Make sure operators follow Owner’s Manual and labels.  
S
S
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.  
S
7079091  
(Found on Scrambler 90 and Sportsman 90  
10  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
S Kids under age 12 should NEVER operate this ATV. Kids  
under 12 have an increased chance of losing control, which  
could result in severe injury or death.  
S Adult supervision is required.  
S Make sure operators follow Owner’s Manual and labels.  
S Make sure operators watch the safety video and pass the  
ATV Training Course.  
S Never operate this ATV on HILLS steeper than 15 degrees  
15°. To prevent flipover on hilly terrain, use throttle  
and brakes gradually.  
11  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
3
4
3
WARNING  
IMPROPER TIRE PRESSURE OR  
OVERLOADING can cause loss of control,  
resulting in SEVERE INJURY OR DEATH.  
TIRE PRESSURE (PSI): FRONT 2 REAR 2  
maximum weight capacity  
(Gross Vehicle Weight) INCLUDING MACHINE,  
DRIVER AND CARGO IS _____ LBS.  
(Found on Scrambler 50 and Scrambler 90)  
12  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
4
WARNING  
Indicates a potential hazard which could  
result in severe injury or death.  
13  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
6
5
14  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
ATTENTION  
D Operation of this  
vehicle without the  
D Specific carburetor jetting  
and adjustments are  
filter element will severely  
damage the engine.  
required depending on temperature  
and altitude. See your Owner’s Manual.  
D Clean air filter often, more  
frequent cleaning required in  
dusty conditions.  
Factory Setting:  
D 40° to 80° F. at 0-3000 feet. (5° to 27°  
C. at 0-900 meters)  
6
(on rear of seat)  
5
15  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
9
8
10  
16  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
WARNING  
7
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.  
9
8
DO NOT TOW FROM RACK OR BUMPER.  
Vehicle damage or tipover may result  
causing severe injury or death.  
DO NOT TOW FROM RACK OR BUMPER.  
Vehicle damage or tipover may result  
causing severe injury or death.  
Maximum Front Rack Load 10 lbs.  
Maximum Rear Rack Load 20 lbs.  
(Found on the Sportsman 90)  
17  
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GENERAL SAFETY AND DESCRIPTION OF LABELS  
10  
MANUFACTURED  
BY: POLARIS IND. INC.  
DATE:  
S
IMPROPER TIRE PRESSURE OR OVERLOADING can cause  
loss of control resulting in SEVERE INJURY OR DEATH.  
VIN:  
TIRE PRESSURE (PSI): FRONT 2 REAR 2  
THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS  
NOT INTENDED FOR USE ON PUBLIC ROADS.  
MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight  
INCLUDING MACHINE, DRIVER AND CARGO IS 423 LBS.)  
CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN  
QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR  
LES CHEMINS PUBLICS.  
S
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.  
(Found on Sportsman 90)  
18  
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OPERATION 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.  
19  
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DAILY PRE-RIDE INSPECTION  
This ATV must be inspected each time before riding to ensure it is in proper  
working order. If proper inspection is not done, severe injury or death could  
result.  
Use the following checklist to verify your machine is in proper working order each time  
you ride.  
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, adjustment.  
4. Throttle - check for free operation and closing  
5. Brakelight - check for proper operation.  
20  
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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. Operators helmet, goggles and clothing  
Indicates a potential hazard which could  
result in severe injury or death.  
21  
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OPERATION 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.  
22  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
arrying a passenger on this ATV.  
HAT CAN HAPPEN  
reatly reduces your ability to balance and control  
is ATV.  
ould cause an accident, resulting in harm to you  
nd/or your passenger.  
OW TO AVOID THE HAZARD  
ever carry a passenger. The long seat is to allow  
e operator to shift position as needed during op-  
eration. It is not for carrying passengers.  
23  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this ATV on paved surfaces, including side-  
walks, paths, parking lots, and driveways.  
WHAT CAN HAPPEN  
The ATV tires are designed for off-road use. Paved  
surfaces may seriously affect handling and control of  
the ATV, and may cause the vehicle to go out of control.  
HOW TO AVOID THE HAZARD  
Avoid operating the ATV on pavement whenever pos-  
sible. If you must ride on a paved surface, go slowly  
and do not make sudden turns or stops.  
24  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this ATV on public streets, roads or  
highways.  
WHAT CAN HAPPEN  
You can collide with another vehicle.  
HOW TO AVOID THE HAZARD  
Never operate this ATV on any public street,  
road or highway, even a dirt or gravel one.  
In many states it is illegal to operate ATVs on  
public streets, roads and highways.  
25  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD Operating this ATV without  
wearing an approved helmet, eye protection and pro-  
ective 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 acci-  
dent 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.  
26  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this ATV after consuming alcohol or drugs.  
WHAT CAN HAPPEN  
Could seriously affect your judgment.  
Could cause you to react more slowly.  
Could affect your balance and perception.  
Could result in an accident.  
HOW TO AVOID THE HAZARD  
Never consume alcohol or drugs before or while driving this ATV.  
27  
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OPERATION 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 acci-  
dent.  
HOW TO AVOID THE HAZARD  
Always travel at a speed which is proper for the terrain, visibility and operating  
conditions; and your experience.  
Indicates a potential hazard which could  
result in severe injury or death.  
28  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Attempting wheelies, jumps and other stunts.  
WHAT CAN HAPPEN  
Increases the chance of an accident, including an  
overturn.  
HOW TO AVOID THE HAZARD  
Never attempt stunts, such as wheelies or jumps.  
Don’t try to show off.  
29  
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OPERATION 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.  
30  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Removing hands from handlebars or feet from footrests during operation.  
WHAT CAN HAPPEN  
Removing even one hand or foot can reduce your ability to control the ATV or  
could cause you to lose your balance and fall off the ATV. If you remove a foot  
from the footrest, your foot or leg may come into contact with the rear wheels,  
which could injure you or cause an accident.  
HOW TO AVOID THE HAZARD  
Always keep both hands on the handlebars and both feet on the footrests of  
your ATV during operation.  
31  
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OPERATION 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.  
32  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Failure to use extra care when operating on  
excessively rough, slippery or loose terrain.  
WHAT CAN HAPPEN  
Could cause loss of traction or vehicle control,  
which could result in an accident, including an  
overturn.  
HOW TO AVOID THE HAZARD  
Do not operate on excessively rough, slippery or loose terrain until you have  
learned and practiced the skills necessary to control the ATV on such terrain.  
Always be especially cautious on these kinds of terrain.  
33  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Turning improperly.  
WHAT CAN HAPPEN  
ATV could go out of control, causing a collision or overturn.  
HOW TO AVOID THE HAZARD  
Always follow proper procedures for turning as described in the Owner’s  
Manual. See page 86 .  
Practice turning at low speeds before attempting to turn at faster speeds.  
Do not turn at excessive speed.  
34  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Climbing hills improperly.  
WHAT CAN HAPPEN  
Could cause loss of control or cause ATV to over-  
turn.  
HOW TO AVOID THE HAZARD  
Always follow proper procedures for climbing hills  
as described in the Owner’s Manual. See pages 91 through 96.  
Always check the terrain carefully before you start up any hill.  
Never climb hills with excessively slippery or loose surfaces. Shift your weight for-  
ward.  
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 ve-  
hicle or person could be on the other side of the hill.  
35  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Going down a hill improperly.  
WHAT CAN HAPPEN  
Could cause loss of control or cause ATV to overturn.  
HOW TO AVOID THE HAZARD  
Always follow proper procedures for going down hills  
as described in the Owner’s Manual. See page 94. NOTE: A special technique  
is required when braking as you go downhill.  
Always check the terrain carefully before you start down any hill. Shift your weight  
backward. Never go down a hill at high speed.  
Avoid going down a hill at an angle which would cause the vehicle to lean sharply  
to one side. Go straight down the hill where possible.  
36  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Improperly crossing hills or turning on hills.  
WHAT CAN HAPPEN  
Could cause loss of control or cause ATV to overturn.  
HOW TO AVOID THE HAZARD  
Never attempt to turn the ATV around on any hill until  
you have mastered the turning technique as described in the Owner’s Manual  
on level ground. See page 96. Be very careful when turning on any hill.  
Avoid crossing the side of a steep hill if possible.  
When crossing the side of a hill: Always follow proper procedures as described  
in the Owner’s Manual. Avoid hills with excessively slippery or loose surfaces.  
Shift your weight to the uphill side of the ATV.  
37  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Stalling, rolling backwards or improperly dismount-  
ing while climbing a hill.  
WHAT CAN HAPPEN Could result in ATV overturn-  
ing.  
HOW TO AVOID THE HAZARD  
Maintain steady speed when climbing a hill.  
If you lose all forward speed: Keep weight uphill. Ap-  
ply the brakes. Lock parking brake after you are stopped.  
If you begin rolling backwards: Keep weight uphill; never apply engine power.  
Never apply the rear brake while rolling backwards. Apply the front brake slowly  
by squeezing the RH lever. When fully stopped, apply rear brake as well, and  
then lock parking brake. Dismount on uphill side, or to either side if pointed  
straight uphill. Turn the ATV around and remount, following the procedure de-  
scribed in the Owner’s Manual. See page 96.  
38  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Skidding or sliding.  
WHAT CAN HAPPEN  
You may lose control of the ATV.  
You may also regain traction unexpectedly, which may cause the ATV to over-  
turn.  
HOW TO AVOID THE HAZARD  
On slippery surfaces, such as ice, go slowly and be very cautious in order to  
reduce the chance of skidding or sliding out of control.  
Indicates a potential hazard which could  
result in severe injury or death.  
39  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Improperly operating over obstacles.  
WHAT CAN HAPPEN  
Could cause loss of control or a collision. Could cause the ATV to overturn.  
HOW TO AVOID THE HAZARD  
Before operating in a new area, check for obstacles.  
Use extreme caution when riding over large obstacles, such as large rocks or  
fallen trees.  
If you cannot avoid obstacles, always follow proper procedures as described in  
the Owner’s Manual.  
40  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Riding on frozen lakes and rivers.  
WHAT CAN HAPPEN  
Severe injury or death can result if the ATV and/or the operator break  
through the ice.  
HOW TO AVOID THE HAZARD  
Never ride your ATV on a frozen body of water.  
41  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD Operating this ATV through deep orfast flowing water.  
WHAT CAN HAPPEN  
Tires may float, causing loss of traction and loss of control, which could lead  
to an accident.  
HOW TO AVOID THE HAZARD  
Avoid operating the ATV through deep or fast flowing water. If you canot avoid  
water which exceeds the recommended maximum depth, go slowly, balance  
your weight carefully avoiding sudden movements, maintain a slow and  
steady forward motion, do not make sudden turns or stops, and do not make  
sudden throttle changes. See page 98.  
Remember that wet brakes may have reduced stopping ability. Test your  
brakes after leaving water. If necessary, apply them several times to let fric-  
tion dry out the pads.  
42  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this ATV with improper tires, or with improper oruneven tire pressure.  
WHAT CAN HAPPEN  
Use of improper tires on this ATV, or operation of this ATV with improper or un-  
even tire pressure, may cause loss of control, and increases the risk of an acci-  
dent.  
HOW TO AVOID THE HAZARD  
Always use the size and type tires specified in the Owner’s Manual Supplement  
for this vehicle.  
Always maintain proper tire pressure as described in the Owner’s Manual Sup-  
plement.  
43  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Overloading this ATV  
WHAT CAN HAPPEN  
Could cause changes in vehicle handling which could lead to an accident.  
HOW TO AVOID THE HAZARD  
Never exceed the stated load capacity for this ATV.  
Cargo should be properly distributed and securely attached.  
44  
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OPERATION WARNINGS  
WARNING  
After a rollover or an accident, have a qualified service dealer check the com-  
plete machine including, but not limited to, brakes, throttle and steering for  
possible damage.  
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.  
Indicates a potential hazard which could  
result in severe injury or death.  
45  
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OPERATION WARNINGS  
WARNING  
POTENTIAL HAZARD  
Operating this ATV with improper modifications.  
WHAT CAN HAPPEN  
Improper installation of accessories or modification of this vehicle may cause  
changes in handling which in some situations could lead to an accident.  
HOW TO AVOID THE HAZARD  
Never modify this ATV through improper installation or use of accessories.  
All parts and accessories added to this vehicle should be genuine Polaris In-  
dustries Inc. or equivalent components designed for use on this ATV; and  
should be installed and used according to instructions. If you have questions,  
consult an authorized Polaris ATV dealer.  
46  
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VEHICLE IDENTIFICATION NUMBERS  
2
47  
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VEHICLE IDENTIFICATION NUMBERS  
Record these numbers from your ATV in the spaces provided.  
1. Engine Serial Number (Left side of engine crankcase)  
2. Frame VIN (found on the front of frame below steering post)  
Remove the spare key and store in a safe place. Your key can be duplicated only  
by obtaining a key blank from Polaris and having it cut by mating it with your existing  
key.  
The vehicle frame and engine serial numbers are important for model identification  
when registering your vehicle, obtaining insurance or whenever replacement parts  
are required. In the event your vehicle were stolen these numbers are essential to  
the recovery and identification of your ATV.  
48  
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CONTROL AND PARTS FUNCTIONS  
Engine Electrical Switches  
1 - Main Switch  
- Located on the  
Right-hand side  
of the Scram-  
blers (A) and on  
the pod of the  
Sportsman (B).  
This switch is  
A
operated with a  
key and must  
B
be turned clock-  
wise to the “on”  
position to start  
the engine.  
1
49  
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CONTROL AND PARTS FUNCTIONS  
2 - Emergency Engine Stop Switch The  
engine will not start or run when the switch is  
in its “off” position. Its purpose is to provide  
the operator with a quick means of engine  
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, slide the stop switch right  
or left to the “off” position.  
OFF  
OFF  
RUN  
2
50  
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CONTROL AND PARTS FUNCTIONS  
3 - Engine Start Button - To start  
the engine, make certain the tether  
switch is securely plugged into the  
machine and attached to the rider’s  
right wrist. Turn the key to the “on”  
position, set the parking brake, and push the  
start button.  
NOTE: Remember to release the  
park brake before driving forward.  
3
51  
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CONTROL AND PARTS FUNCTIONS  
Engine or driveline damage could occur if the machine is driven without the  
park brake released.  
This ATV is not equipped with lighting. This ATV is designed for off-road  
use only and must not be ridden on streets or highways. Use caution and  
drive at reduced speeds in conditions of reduced visibility. Do not operate  
this machine after dark.  
52  
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CONTROL AND PARTS FUNCTIONS  
Engine Throttle  
Indicates a potential hazard which could  
result in severe injury or death.  
Do not start or operate an ATV with sticking or improperly operating throttle  
controls. A stuck or improperly operating throttle could cause an accident  
resulting in severe injury or death.  
Always contact your dealer for service repairs whenever throttle problems  
arise.  
Failure to check or maintain proper operation of the throttle system can re-  
sult in the throttle lever sticking during riding and cause an accident.  
Always check the lever for free movement and return before starting the en-  
gine and occasionally during riding.  
53  
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CONTROL AND PARTS FUNCTIONS  
Throttle Lever  
Engine speed and vehicle movement are con-  
trolled by pressing the throttle lever. The  
throttle lever (1) is spring loaded and engine  
speed returns to idle when the lever is re-  
leased.  
This vehicle is equipped with an Electronic  
Throttle Control (ETC) which is designed to  
reduce the risk of a frozen or stuck throttle. In  
the event the throttle cable should stick in an  
open position, the engine will stop and power  
to the rear wheels will cease when the opera-  
tor releases the throttle lever.  
54  
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CONTROL AND PARTS FUNCTIONS  
The Electronic Throttle Control (ETC) stops the engine in the event of a  
throttle system malfunction and is provided for your safety. Do not at-  
tempt to modify the ETC system or replace it with any after market throttle  
mechanism.  
55  
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CONTROL AND PARTS FUNCTIONS  
Switches  
Each Polaris ATV has a main switch. It is located on the right hand side of the  
machine or headlight pod and operated with a key.  
Indicator Lights  
Each Polaris ATV has indicator lights. This model has a low oil warning light.  
When this red dot is lit, it is indicating a low oil level.  
56  
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CONTROL AND PARTS FUNCTIONS  
Front and Rear Brakes  
To activate the rear brake (A),  
squeeze the left hand lever to-  
ward the handlebar.  
The front brakes (B) are activated  
by squeezing the lever on the RH  
handlebar.  
B
A
Always apply both brakes at the  
same time or loss of vehicle con-  
trol can occur resulting in seri-  
ous injury or death.  
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CONTROL AND PARTS FUNCTIONS  
Parking Brake  
Always check to be sure that the parking brake has been disengaged before  
operating the ATV. An accident could result causing severe injury if the park-  
ing brake is left on while the ATV is operated.  
Setting the Parking Brake  
1. Squeeze the left hand brake lever (A).  
A
2. Push the park brake lock (B) down. This will pre-  
vent the lever from returning to the released  
position.  
B
58  
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CONTROL AND PARTS FUNCTIONS  
3. To release the parking brake lock, squeeze the brake lever. The parking brake will  
release automatically.  
Important Safeguards  
NOTE: This vehicle has a PVT system which is always in forward. Always lock the  
park brake before starting the engine.  
Always lock the parking brake whenever the vehicle is left unattended.  
Before starting the engine, make certain the park brake is fully locked. Since the  
machine has a transmission that is always in forward, throttle activation to warm  
the engine will make the machine go forward if the park brake is not locked.  
Once the engine has warmed enough for operation, release the park brake and  
gently apply the throttle to go forward.  
59  
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CONTROL AND PARTS FUNCTIONS  
Gasoline is highly flammable and explosive under certain conditions.  
D Always exercise extreme caution whenever handling gasoline.  
D Always refuel with the engine stopped and outdoors or in a well ventilated  
area.  
D Do not smoke or allow open flames or sparks in or near the area where re-  
fueling is performed or where gasoline is stored.  
D Do not over fill the tank. Do not fill the tank neck.  
D If you get gasoline on your skin or clothing, immediately wash it off with  
soap and water and change clothing.  
D Never start the engine or let it run in an enclosed area. Gasoline powered  
engine exhaust fumes are poisonous and can cause loss of consciousness  
and death in a short time.  
D Shut off fuel valve whenever the ATV is stored or parked.  
60  
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CONTROL AND PARTS FUNCTIONS  
Indicates a potential hazard which  
could result in severe injury or death.  
WARNING  
The engine exhaust from this prod-  
uct contains chemicals known to  
cause cancer, birth defects or other  
reproductive harm.  
61  
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CONTROL AND PARTS FUNCTIONS  
PVT System  
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 fol-  
lowing responsibilities to make sure this system remains safe:  
D 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 bal-  
ance, creating vibration and additional loads on components.  
D Routine maintenance is the responsibility of the owner. Always follow rec-  
ommended maintenance procedures. See your dealer!  
D This PVT system is intended for use on Polaris products only.  
D The PVT housing must be securely in place during operation.  
Failure to comply with this warning can result in severe injury or death.  
62  
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CONTROL AND PARTS FUNCTIONS  
Engine Fuel and Oil System  
Fuel System  
The fuel tank filler cap (1) is located directly  
behind the handlebar. The tank has a ca-  
pacity of 1.3 gallons (5 liters). Use un-  
leaded gasoline with a minimum pump oc-  
tane number of 87 octane.  
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CONTROL AND PARTS FUNCTIONS  
The fuel valve is located on the engine, be-  
hind the right front fender and has three  
positions:  
OFF: For vehicle storage and whenever  
transporting.  
ON: For normal operation.  
Scrambler  
Fuel Valve  
RES: For reserve supply in the event of  
main supply exhaustion.  
Sportsman  
Fuel Valve  
NOTE: There is about a 7 to 10 mile (11.2  
to 16 km) range on reserve gas. Always  
refill the gas tank as soon as possible after  
having used the reserve supply.  
Always return valve to “on” position after  
refueling machine.  
64  
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CONTROL AND PARTS FUNCTIONS  
Engine Fuel Safety/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.  
Use only Polaris injection oil. Never substitute or mix oil brands. Serious en-  
gine damage and voiding of warranty can result.  
To avoid serious engine damage always top off the oil level when refueling.  
65  
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CONTROL AND PARTS FUNCTIONS  
Oil System  
The oil tank (1) is located under the seat and has a capacity of 12 ounces (1 liter).  
To remove the seat,  
1
reach under the rear of  
the cab and pull back on  
the seat latch. To re-  
place the seat, set it in  
place and push down on  
the rear of seat. Always  
make sure the seat is  
locked in place before riding.  
Do not attempt to release the seat latch unless the machine has not been  
run for at least an hour. The exhaust gets very hot when the machine is run  
and can cause serious burns.  
66  
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CONTROL AND PARTS FUNCTIONS  
Engine warranty coverage may become void if you use a brand other than Polaris  
in your machine.  
Polaris 2-Cycle Lubricants  
Polaris has a family of premium oils available for use in all our products and highly  
recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Po-  
laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.  
67  
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CONTROL AND PARTS FUNCTIONS  
Polaris Premium 2-cycle lubricants are the most advanced formulation of oils spe-  
cifically designed for today’s 2-cycle engines. Months of lab and field tests have  
resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubri-  
cants provide additives for 2-cycle engines lacking in today’s fuel that keep ring  
grooves cleaner for less ring sticking and provide improved overall engine cleanli-  
ness. With new generation lubricity technology, they excel in meeting the lubrica-  
tion demands of today’s high performance 2-cycle engines. These are optimum  
oils recommended for liquid cooled and air cooled 2-cycle engines. We believe  
these oils are the best available in the market today.  
Premium 2-Cycle Oil  
Polaris also has a TC-W3 premium oil available for use in all of our 2 cycle prod-  
ucts. We highly recommend its use if premium gold synthetic is not used. The  
only oil recommended for this ATV is Polaris brand oil.  
Polaris Premium 2-cycle oils will readily mix with each other, however do not mix  
Polaris Premium 2-cycle oils with any other oils as they may not be compatible  
and engine damage may occur.  
68  
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CONTROL AND PARTS FUNCTIONS  
Kick Starter  
If the battery is weak and cannot start the en-  
gine, kick start lever will allow vehicle opera-  
tion until repairs can be made.  
1. Be certain your vehicle is on a level surface  
and the parking brake is set. See page 58.  
2. Fold out the kick start lever (A) which is on the  
left hand side of the machine.  
3. Turn the key to “ON” and make sure the stop  
switch is in the “RUN” position.  
A
4. Placing your foot on the kick start, push your  
heel downward to crank the engine.  
5. Once the engine has started, fold the kickstart lever back into place.  
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STARTING THE ENGINE  
Procedure for Starting a Cold Engine  
Indicates a potential hazard which could  
result in severe injury or death.  
Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poi-  
sonous and can cause severe injury or death. Always start engines outdoors.  
You must allow your vehicle adequate warm up time before operating or en-  
gine damage could result.  
70  
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STARTING THE ENGINE  
1. Set the parking brake.  
2. Turn the fuel tank valve to ON.  
3. Sit on the vehicle.  
4. Attach tether strap to machine and wrist.  
5. Turn the engine stop switch to RUN.  
6. Turn the ignition key to ON.  
7. Press the starter button. NOTE: The rear brake lever must be engaged or the en-  
gine will not start.  
8. Do not press the throttle while starting the engine.  
9. Activate the starter for a maximum of five seconds, releasing the button when the  
vehicle starts. If engine does not start, release the starter and wait five seconds;  
then activate the starter for another five seconds. Repeat this procedure until en-  
gine starts.  
After the engine starts, vary the engine RPM slightly with the throttle to aid in  
warm up until the engine idles smoothly.  
71  
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RIDING GEAR  
Safe Riding Gear  
L
Always wear clothing suited to the type of riding you  
are doing. ATV riding requires special protective  
clothing which will make you feel more comfortable  
and reduce chances of injury.  
1. Helmet  
Your helmet is the most important piece of protec-  
tive gear for safe riding. A helmet can prevent a  
severe head injury.  
Select an approved helmet which 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.  
L
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RIDING GEAR  
2. Eye Protection  
Do not depend on sunglasses for proper eye protection. A pair of goggles or hel-  
met 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 type boots with heels, such as  
moto-cross boots.  
5. Clothing  
To protect your body, long sleeves and pants should always be worn. Riding  
pants with kneepads, a jersey and shoulder pads provide the best protection.  
73  
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VEHICLE BREAK-IN PERIOD  
2-Cycle Engines  
The break in period for your new Polaris ATV is defined as the time it takes to use  
the first tank of gasoline. No single action on your part is as important as a proper  
break in period. Careful treatment of a new engine will result in more efficient per-  
formance and longer life for the engine. Perform the following procedures careful-  
ly.  
Use only Polaris injection oil. Never substitute or mix oil brands. Serious en-  
gine damage and voiding of warranty can result.  
1. Mix 6.4 ounces of injection oil to two gallons of gasoline in a suitable gas can. Fill  
the fuel tank as outlined on page 65.  
2. Fill the oil tank with Polaris injection oil.  
74  
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VEHICLE BREAK-IN PERIOD  
3. Drive slowly at first. Select an area which is open and will give you room to familiar-  
ize yourself with vehicle operation and handling.  
Do not operate at full throttle or high speeds for extended periods during the  
first three hours of use. Excessive heat can build up and cause damage to  
close fitted engine parts.  
4. Vary the throttle positions.  
5. Perform regular checks on fluid levels, controls and all important areas on the ve-  
hicle as outlined earlier on the daily pre-ride inspection checklist found on page 20.  
75  
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VEHICLE BREAK-IN PERIOD  
After the break in period the oil injection system provides the necessary engine  
lubrication without the need for pre-mixed fuel.  
Fill the oil tank when you refuel your ATV. If you don’t serious engine  
damage could result.  
After the first tank of pre-mixed fuel has been used please verify that the oil level  
in the oil tank has dropped, indicating that the oil pump is functioning properly. If  
the level has not dropped, see your dealer for oil pump bleeding and repeat the  
pre-mix procedure.  
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CARRYING LOADS  
The Sportsman 90 has been designed to carry a certain amount of load. CARGO  
WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and  
mounted as low as possible. When operating over rough or hilly terrain, reduce  
speed and cargo to maintain stable driving conditions. Never exceed the weights  
specified and never attempt to carry cargo on the Scrambler models.  
Correct loading of this vehicle is necessary to maintain proper stability and op-  
erating characteristics. Overloading or incorrect positioning of the load affects  
the vehicle’s turning, stopping distance and stability. Failure to follow loading  
requirements could cause severe injury or death.  
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CARRYING LOADS  
2/3 of Load on  
Rear Rack  
1/3 of Load on  
Front Rack  
Important Safeguards  
To reduce risk of injury or machine damage when carrying loads, read and  
follow the warnings listed below:  
D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING  
WHEN CARRYING CARGO.  
D 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.  
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CARRYING LOADS  
D 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.  
D 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.  
D LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE.  
Carrying loads high on the racks raises the center of gravity of the ve-  
hicle 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.  
D 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.  
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CARRYING LOADS  
D EXTREME CAUTION MUST BE USED when operating with loads extend-  
ing over the rack sides. Stability and maneuverability may be adversely  
affected, causing the machine to overturn.  
D DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.  
80  
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DAILY PRE-RIDE CHECK  
You must inspect your ATV each time before riding to ensure it is in proper  
working order. If proper check is not done, severe injury or death could result.  
81  
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DAILY PRE-RIDE CHECK  
Use the following checklist to verify your machine is in proper working order each  
time you ride.  
Item/Inspection Procedure  
1. Tires - check condition and pressures  
2. Fuel and oil tanks - fill both tanks to their proper levels  
3. All brakes - check operation and adjustment.  
4. Throttle - check for free operation and closing  
5. Brakelight - check for proper operation.  
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  
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DAILY PRE-RIDE CHECK  
8. Drive chain - condition and slack; refer to drive chain adjustment  
9. Air cleaner element - check for dirt; clean or replace  
10. Steering - check for free operation noting any unusual looseness in any area  
11. Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fas-  
teners  
12. Operators helmet, goggles and clothing  
Indicates a potential hazard which could  
result in severe injury or death.  
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RIDING  
84  
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RIDING  
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 sur-  
faces.  
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RIDING  
Making Turns  
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RIDING  
Practice making turns at slow speeds.  
Polaris ATVs are equipped with a solid rear axle which drives both rear wheels  
equally at all times. This means that the wheel on the outside of the turn must  
travel a greater distance than the inside wheel when turning and the inside tire  
must slip traction slightly. 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 foot-  
rest. This technique alters the balance of traction between the rear wheels allow-  
ing the turn to be made smoothly.  
Avoid turning at sharp angles. Tipover and severe injury may result.  
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RIDING  
Riding On Slippery Surfaces  
Whenever riding on slippery surfaces such as wet trails or loose gravel, or dur-  
ing cold freezing weather, special attention must be paid to prevent vehicle  
turnover. Always:  
88  
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RIDING  
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.  
4. Never apply brakes during a skid. Complete loss of ATV control can result.  
5. Do not operate on excessively slippery surfaces if possible to avoid.  
6. Always reduce speed and use additional caution.  
Failure to exercise care when operating the ATV on slippery surfaces can be  
dangerous.  
Loss of tire traction and vehicle control can result in an accident, including an  
overturn.  
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RIDING  
Traveling Uphill  
90  
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RIDING  
Do not operate this machine on hilly terrain. If you cannot avoid operating in  
hilly terrain, use extreme caution. Braking and handling are greatly affected.  
Loss of vehicle control or overturning of the ATV could occur causing severe  
injury or death.  
If you have to travel uphill always travel straight uphill and:  
1. Avoid steep hills (15_ maximum).  
2. Keep both feet on the footrests.  
3. Transfer your weight forward.  
4. Proceed at a steady rate of speed and throttle opening.  
5. Remain alert and be prepared to take emergency action. This may include quick  
dismounting of the ATV.  
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RIDING  
Sidehilling  
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RIDING  
Avoid traveling across the side of a hill at all costs. In the event you do enter  
into a situation where sidehilling is unavoidable, always:  
1. Slow down.  
2. Lean into the hill transferring your upper body weight up hill while keeping your feet  
on the footrests.  
3. Steer slightly into the hill to maintain vehicle directions.  
If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dis-  
mount on the uphill side immediately!  
Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle  
control or overturning of the ATV could occur causing severe injury or death.  
93  
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RIDING  
Traveling Downhill  
94  
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RIDING  
Whenever descending a hill, always:  
1. Drive directly downhill.  
2. Transfer your weight to the rear of the vehicle.  
3. Slow down.  
4. Apply the the front and rear brakes at the same time and very slightly to aid in slow-  
ing.  
Do not travel at excessive speeds. It is dangerous and can cause loss of ve-  
hicle control and tipping, resulting in severe injury or death.  
95  
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RIDING  
Turning Around On A Hill  
8’  
Uphill  
If the ATV stalls while climbing a hill, never back it down the hill! One maneuver  
which can be used when it is necessary to turn around while climbing a hill is  
the K-turn.  
96  
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RIDING  
1. Stop and lock the parking brake while maintaining body weight uphill.  
2. Shut off engine.  
3. Dismount on left or uphill side of ATV.  
4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV).  
5. While holding service brake, release parking brake lock and slowly allow ATV to  
roll around to your right until ATV is pointing across the hill or slightly downward.  
6. Lock the parking brake and remount ATV from the uphill side, maintaining body  
weight uphill.  
7. Restart engine, release parking brake, and proceed slowly, controlling speed with  
the service brake, until ATV is on reasonably level ground.  
Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV  
could occur resulting in severe injury or death.  
97  
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RIDING  
Crossing Streams  
Your Polaris ATV can operate through water up to depths just below the foot-  
rests. Before fording streams always:  
98  
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RIDING  
1. Determine water depths and current.  
2. Choose a crossing where both banks have gradual inclines.  
3. Proceed slowly, avoiding rocks and obstacles if possible.  
4. After crossing, dry the brakes by applying light pressure to the levers until braking  
action is normal. If you do not perform this procedure, your brakes may be ineffec-  
tive.  
D Avoid operating the ATV through deep or fast flowing water. If you cannot avoid  
water which exceeds the recommended maximum depth, go slowly, balance  
your weight carefully, avoid sudden movements, maintain a slow and steady for-  
ward motion. Do not make sudden turns or stops and do not make sudden  
throttle changes.  
NOTE: If the vehicle is run in water, it is critical the machine is serviced as out-  
lined in the maintenance chart beginning on page 117. The following areas need  
special attention: engine oil, transmission oil, front and rear gearcases, and all  
grease fittings.  
99  
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RIDING  
Trail Obstacles  
100  
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RIDING  
Keep Alert!  
Look ahead and learn to read the trail as you ride. Stay on the right side of the  
trail, if possible, and be constantly alert for hazards such as logs, rocks and low  
hanging branches.  
Not all obstacles are visible. Travel with caution on trails. severe injury or  
death can result if your machine comes in contact with a hidden obstacle.  
Indicates a potential hazard which could  
result in severe injury or death.  
101  
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RIDING  
Parking on an Incl
102  
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RIDING  
Whenever the Vehicle is Parked  
1. Turn the engine off.  
2. Set the parking brake.  
3. Avoid parking on an incline. If it is necessary to park on an incline, always block  
the rear wheels on the down hill side as shown above.  
4. Shut off fuel supply.  
103  
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PVT SYSTEM OPERATION  
PVT System  
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 follow-  
ing responsibilities to make sure this system remains safe:  
D 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 bal-  
ance, creating vibration and additional loads on components.  
D Routine maintenance is the responsibility of the owner. Always follow rec-  
ommended maintenance procedures. See your dealer!  
D This PVT system is intended for use on Polaris products only.  
D The PVT housing must be securely in place during operation.  
Failure to comply with this warning can result in severe injury or  
death.  
104  
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PVT SYSTEM OPERATION  
If the vehicle is operated in dusty areas, it will be necessary to clean the filter more  
often. To clean the PVT filter:  
1. Remove the screws and the crankcase cover.  
2. Remove the screws and the filter cover.  
3. Soak the filter in a mild detergent and rinse with clean water.  
4. Allow the filter to air dry and reinstall it.  
If your vehicle is operated in salt water areas, it must be rinsed with fresh water  
to prevent corrosion that can be caused by exposure to seawater.  
105  
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BATTERY  
Battery  
Only adults should ever touch the battery. Never allow children to handle  
a battery or service a battery in any way.  
Whenever removing the battery, disconnect the negative (black) cable  
first. When reinstalling the battery, connect the negative (black) cable last  
or an explosive situation could result causing serious injury or death.  
106  
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BATTERY  
Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns  
can result from contact with skin, eyes or clothing. Antidote:  
External: Flush with water.  
Internal: Drink large quantities of water or milk. Follow with milk of mag-  
nesia, beaten egg, or vegetable oil. Call physician immediately.  
Eyes: Flush with water for 15 minutes and get prompt medical attention.  
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.  
away. Ventilate when charging or using in an enclosed space. Always  
shield eyes when working near batteries. KEEP OUT OF REACH OF  
CHILDREN.  
107  
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BATTERY  
Replenishing the Battery Fluid  
A poorly maintained battery will deteriorate rapidly.  
Check the battery fluid level often. The fluid level  
should be kept between the upper and lower level  
marks.  
To refill use only distilled water. Tap water contains  
minerals which are harmful to a battery.  
Maintain  
between  
upper and  
lower level  
marks  
108  
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BATTERY  
Battery Removal  
1. Disconnect hold down straps holding the electrical box and battery in position.  
2. Disconnect the black (negative) battery cable first.  
3. Disconnect the red (positive) battery cable next.  
4. Lift the battery out of the ATV, being careful not to tip it sideways and spill electro-  
lyte.  
If electrolyte spills, immediately wash it off with a solution of one tablespoon  
baking soda and one cup water to prevent damage to the ATV.  
Indicates a potential hazard which could  
result in severe injury or death.  
109  
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BATTERY  
Battery Installation and Connections  
To avoid the possibility of explosion, always connect battery cables in the order  
specified. Red (positive) cable first; black (negative) cable last. An exploding  
battery can cause serious injury or death.  
Battery terminals and connections should be kept free of corrosion.  
If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a  
solution of one tablespoon baking soda and one cup water. Rinse well with tap  
water and dry off with clean rags. Coat the terminals with dielectric grease or pe-  
troleum jelly.  
Be careful not to allow cleaning solution or tap water into the battery.  
110  
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BATTERY  
1. Set the battery in its holder.  
2. First connect and tighten the red (positive) cable.  
3. Second connect and tighten the black (negative) cable.  
4. Attach the hold down strap.  
5. Verify that cables are properly routed.  
NOTE:  
D When your ATV is placed in storage for three months or more, the battery  
should be removed, charged to proper level, and stored in a cool dry place.  
D Before reusing, take the battery to your dealer for testing and recharging.  
D When installing a new battery, make certain it is fully charged prior to it’s initial  
use. Using a battery that is not fully charged can damage the battery resulting  
in a shorter life of the battery. It can also hinder vehicle performance.  
111  
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NOISE EMISSION CONTROL  
SYSTEM REGULATION  
TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!  
U.S. Federal law prohibits the following acts or the causing thereof:  
(1) The removal or rendering inoperative by any person other than for purposes of  
maintenance, repair, or replacement of any device or element of design incorpo-  
rated into any new vehicle for the purpose of noise control prior to its sale or deliv-  
ery to the ultimate purchaser or while it is in use or  
(2) the use of the vehicle after such device or element of design has been re-  
moved or rendered inoperative by any person.  
ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BE-  
LOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING:  
1. Removal or alteration or the puncturing of the muffler or any engine component  
which conducts removal of engine exhaust gases.  
112  
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NOISE EMISSION CONTROL  
SYSTEM REGULATION  
2. Removal or alteration or the puncturing of any part of the engine air induction sys-  
tem.  
3. Replacement of any vehicle parts with parts not in compliance with federal regula-  
tions.  
4. Lack of proper maintenance.  
CAUTION: Remember, exhaust system components are very hot during and after  
use of ATV.  
D Do not touch exhaust system components. Serious burns can result.  
D Be especially careful when traveling through tall grass. The potential for fire ex-  
ists.  
113  
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NOISE EMISSION CONTROL  
SYSTEM REGULATION  
USFS Approved Spark Arrestor  
Most Polaris ATVs have mufflers that were tested and approved in accordance  
with the USFS Forest Service Standard 5100-1A.  
114  
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MAINTENANCE  
Tool Kits  
To help you perform routine maintenance, a tool kit is provided in the storage  
compartment under the seat. Items included in the kits are:  
2-cycle engines  
D spark plug wrench with Phillips head screwdriver  
D tire pressure gauge  
Periodic Maintenance Schedule  
Careful periodic maintenance will help keep your vehicle in the safest, most reli-  
able condition. Inspection, adjustment and lubrication intervals of important com-  
ponents are explained in the following chart on the following pages.  
115  
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MAINTENANCE  
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. If you are not familiar with safe service and adjustment proce-  
dures, have a qualified dealer perform these operations.  
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection  
may reveal the need for replacement parts. Always use genuine Polaris parts  
available from your Polaris dealer.  
Service and adjustments are critical. If you are not familiar with safe service and  
adjustment procedures, have a qualified dealer perform these operations.  
Due to the nature of the adjustments marked with a J on the following chart, it  
is recommended that service be performed by an authorized Polaris dealer.  
116  
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MAINTENANCE  
More often under severe use, such as dirty or wet conditions  
"
Item  
Hours  
or  
Miles  
When  
Remarks  
Brake System  
Tires  
Pre-ride Pre-ride Pre-ride inspection item  
Pre-ride Pre-ride Inspect daily, pre-ride inspection item  
Pre-ride Pre-ride Pre-ride inspection item  
Wheels  
Frame nuts, bolts, Pre-ride Pre-ride Pre-ride inspection item  
fasteners  
Oil Level  
Daily  
Daily  
Daily  
Daily  
Check when refueling  
Inspect-Clean  
"
Air Filter  
J
Brake pad wear  
10  
Monthly Inspect periodically  
hrs/100  
miles  
Battery  
20 hrs  
Monthly Check Terminals/clean/check fluid level  
117  
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MAINTENANCE  
Periodic Maintenance Schedule (Cont.)  
Due to the nature of the adjustments marked with a J on the following chart, it is  
recommended that service be performed by an authorized Polaris dealer.  
"
More often under severe use, such as dirty or wet conditions  
Item  
Hours  
or  
Miles  
When  
Remarks  
Oil Pump Cable  
50 hrs  
6 months Inspect, adjust, lubricate, replace if re-  
quired  
Carburetor Float  
Bowl  
50 hrs  
6 months Drain bowl periodically and prior to storage  
118  
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MAINTENANCE  
Item  
Hours  
or  
Miles  
When  
Remarks  
J
Throttle Cable/  
ETC Switch  
50 hrs  
6 months Inspect-adjust, lubricate, replace if neces-  
sary; pre-ride inspection item  
"
"
"
"
"
Steering  
50 hrs  
50 hrs  
6 months Inspect daily, lubricate  
Rear Axle  
6 months Inspect bearings, Lube  
Front Suspension 50 hrs  
6 months Inspect--lubricate, tighten fasteners  
6 months Inspect, tighten fasteners  
Rear Suspension  
Drive Chain  
50 hrs  
50 hrs  
6 months Inspect daily, adjust and lubricate if need-  
ed  
J
Clutches (drive  
and driven)  
100 hrs 12  
months  
Inspect, clean  
119  
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MAINTENANCE  
Due to the nature of the adjustments marked with a J on the following chart, it is  
recommended that service be performed by an authorized Polaris dealer.  
"
More often under severe use, such as dirty or wet conditions  
Item  
Hours  
or  
Miles  
When  
Remarks  
Engine Mounts  
Spark Plug  
100 hrs 12 months Inspect  
100 hrs 12 months Inspect--replace if necessary  
100 hrs 12 months Inspect and adjust as needed  
J
Ignition Timing  
120  
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MAINTENANCE  
Item  
Hours  
or  
Miles  
When  
Remarks  
J
J
Fuel System  
100  
12 months Check for leaks at tank cap, lines, fuel  
valve, filter, pump and carburetor. Re-  
place lines every two years.  
hours  
Fuel Filter  
100 hrs 12 months Replace annually  
100 hrs 12 months Clean out  
Spark arrestor  
J
J
J
Front wheel bear-  
ings  
300 hrs 36 months Inspect, replace if necessary  
Idle Speed  
As Re- As Re-  
Adjust  
quired  
quired  
Toe adjustment  
As re-  
quired  
As re-  
quired  
Periodic inspection, adjust when parts  
are replaced  
121  
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MAINTENANCE  
Lubrication Recommendations  
Item  
Lube Rec.  
Polaris  
Injection Oil  
Method  
Frequency*  
1. Engine Oil  
Fill oil tank. See page 63. As needed,  
when refueling  
2. Transmission Oil  
Polaris Premium See Page 146  
Synthetic gear  
case lube  
Change annually  
or at 100 hours  
122  
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MAINTENANCE  
Lubrication Recommendations  
2. Transmission  
(plug)  
Operating  
Range  
123  
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MAINTENANCE  
3. Drive Chain  
O-Ring chain lube or Lubricate as often as re-  
As required  
SAE 80/90  
quired. Before each ride  
in wet conditions  
4. Front A-Arm  
L
Grease **  
Locate fittings and grease Every 3  
months or 50  
hours  
L More often under severe use, such as wet or dusty conditions.  
**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such  
as Conoco Superlube M or Mobilegrease Special.  
+ Grease every 40 hours or approximately 500 miles, or after submerging in water  
or before long periods of storage or after pressure washing. Always use Polaris  
Premium U-Joint Lube for maximum service of these driveline components (PN  
2871515 3 oz.)(PN 2871551 14 oz.).  
∆ When suspension action becomes stiff or after washing.  
124  
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MAINTENANCE  
NOTE: Hours are based on 10 mph average.  
4.  
125  
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MAINTENANCE  
Periodic Maintenance Record  
Use the following chart to record periodic maintenance work:  
Maintenance  
Interval  
Performed  
Servicing Servicing  
Remarks  
Date  
Dealer  
or Person  
First 5 Hrs.  
25 Hrs.  
50 Hrs.  
75 Hrs.  
100 Hrs.  
126  
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MAINTENANCE  
Maintenance  
Interval  
Performed  
Servicing Servicing  
Remarks  
Date  
Dealer  
or Person  
127  
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MAINTENANCE  
Improper adjustment of the handlebars or incorrect torquing of the adjuster  
block tightening bolts can cause limited steering or loosening of the handle-  
bars, resulting in loss of control and possible serious personal injury or death.  
Handlebar Adjustment  
Your ATV has handlebars which can be adjusted for your personal fit.  
1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to  
remove the upper “headlight” pod. On other models remove the handlebar cover.  
128  
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MAINTENANCE  
2. Loosen the four bolts.  
3. Adjust handlebar to desired height.  
Be sure handlebars do not hit gas tank  
or any other part of machine when  
turned fully to left or right.  
4. Torque handlebar adjuster block bolts  
to 7.3 ft. lbs.  
NOTE: Tighten bolts so there is an  
equal gap at the front and rear of the  
handlebar block. Improper gap will re-  
sult in improper fit of upper pod.  
129  
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MAINTENANCE  
The following items should be checked occasionally for tightness; or if they have  
been loosened for maintenance service.  
Axle and Wheel Nut Torque Specifications  
Specification  
Front Spindle Nuts  
Rear Spindle Nuts  
43 ft. lbs  
80 ft. lbs.  
NOTE: All nuts that have a cotter pin installed must be serviced by an autho-  
rized Polaris Dealer.  
Front Wheel Hub Tightening  
Front wheel bearing tightness and spindle nut retention are critical component op-  
erations. Service work must be performed by your authorized Polaris dealer.  
130  
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MAINTENANCE  
Rear Spring Adjustment  
The rear shock absorber spring is ad-  
justed by rotating the adjuster in the  
direction required to increase or decrease  
spring tension.  
Rear Spring  
Adjustment  
Cam  
131  
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MAINTENANCE  
Air Cleaner  
Inspect the filter weekly or after every 50 hours of operation. If the vehicle is rid-  
den in wet or dusty conditions, clean the filter more often.  
Never operate the ATV with the filter element removed. Dirt will enter the  
engine causing serious rapid wear and damage to the engine.  
132  
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MAINTENANCE  
To clean the filter:  
1. Remove the screws on  
the airbox (A) and re-  
move the filter (B).  
B
2. Soak the filter in a mild  
detergent and rinse it in  
clean water.  
3. Let the filter air dry and  
reinstall in the air box.  
A
133  
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MAINTENANCE  
Steering Inspection  
The steering assembly of the machine should be checked periodically for loose  
nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them  
before riding your vehicle.  
Camber and Caster  
The camber and caster are non-adjustable.  
Do not attempt to adjust the tie rod for toe alignment. Severe injury or death  
can result from improper adjustment. Contact your Polaris dealer. He/she has  
the training and tools to make these adjustments.  
134  
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MAINTENANCE  
Throttle Stop System  
D
E
This vehicle is equipped with a  
throttle stop system that controls  
how far the throttle opens. Using  
this feature, adults can limit how  
fast the machine will travel. To  
adjust, loosen the jam nut (D)  
Turn the screw (E) inward to re-  
duce speed and outward to in-  
crease speed. Tighten jam nut  
after adjusting.  
135  
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MAINTENANCE  
Toe Alignment  
You can check the toe alignment of the  
vehicle using the following method.  
The recommended toe alignment is  
1/8″ to 1/4″ (.3 to .6 cm) toe out. If you  
discover improper adjustment have  
your dealer correct it.  
1. Set the handlebars in a straight ahead  
position and hold them in this position.  
NOTE: The steering frog can be used  
as an indicator of whether the handle-  
bars are straight. The frog should al-  
ways point straight back from the  
steering post.  
136  
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MAINTENANCE  
Toe Alignment (cont.)  
2. Place stands in front of the machine, perpendicular to the rear tires.  
3. Tie an elastic string around the stands, making sure string just touches side  
surface of the rear tires on each side of machine and goes around the stands  
in front of the machine.  
4. Measure from string to rim at front and rear of front rim. Rear rim measure-  
ment should be 1/16″ - 1/8″ (.2 to .3 cm) more than front rim measurement.  
5. If this measurement needs to be adjusted, contact your dealer for service.  
137  
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MAINTENANCE  
Brake Adjustment  
Periodically check the freeplay of the  
front and rear brakes. Refer to the chart  
below for the acceptable range of free-  
play for your machine.  
To adjust the front brake, turn the adjust-  
ment knob (A) until the freeplay is accept-  
able.  
A
138  
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MAINTENANCE  
To adjust the rear brake, turn the adjuster  
nut (B) until the proper freeplay is at-  
tained.  
B
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MAINTENANCE  
Brake Freeplay Adjustment  
Model  
Front  
Rear  
Sportsman 90  
.39″ - .78″  
10 mm - 20 mm  
.39″ - .78″  
10 mm - 20 mm  
Scrambler 90  
Scrambler 50  
.39″ - .78″  
.39″ - .78″  
10 mm - 20 mm  
10 mm - 20 mm  
.1″ - .39 ″  
2.5mm - 9.9 mm  
.15″ - .30″  
3.8mm - 7.6mm  
140  
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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 bet-  
ween 1/16″ and 1/8 ″ (1.5mm -  
3.2mm) (C). If adjustment is re-  
quired, turn the adjustment nut (D)  
until the freeplay falls in to the ac-  
ceptable limit.  
D
C
Indicates a potential hazard which could  
result in severe injury or death.  
141  
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MAINTENANCE  
Spark Plugs  
The spark plug required for this machine is NGK BP7HS or NGK BPR7HS. Incor-  
rect spark plug gap can cause the spark plugs to foul. The spark plug gap should  
be between 0.6 - 0.7 mm.  
The spark plug and its condition is indicative of engine operation. The spark plug  
firing end condition should be read after the engine is warmed up and the vehicle  
is driven at higher speeds. Immediately check the spark plug for correct color.  
1. Normal  
The 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.  
142  
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MAINTENANCE  
2. Wet Fouled  
The insulator tip is black. A damp oil film covers the firing end. There may be a  
carbon layer over the entire nose. Generally, the electrodes are not worn. Gener-  
al causes are excessive oil, use of non-recommended injection oil, improper use  
of the choke, or incorrect carburetion adjustments.  
143  
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MAINTENANCE  
Spark Plug Removal and Replacement  
Never attempt to remove a spark plug while the engine is warm. The exhaust  
system or engine could burn you causing severe injury.  
The spark plug is removed by using the special wrench provided in the tool pouch.  
Remove the spark plug cap and then the spark plug by rotating counterclockwise.  
Reverse the procedure for spark plug installation. Torque to 17 ft. lbs.  
Never deviate from the recommended spark plug as engine damage can occur.  
144  
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MAINTENANCE  
Cylinder Head/Cylinder Base Fastener Torque  
(2-Cycle Models)  
Have your dealer check the ATV cylinder head and cylinder base fasteners for  
proper torque at the first service or after 25 hours.  
Indicates a potential hazard which could  
result in severe injury or death.  
145  
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MAINTENANCE  
Transmission Lubrication  
The transmission dipstick (A) is located on  
the top of the transmission.  
The transmission lubricant level should be  
checked monthly. Transmission oil should  
be changed annually. With the ATV on a  
level surface, remove fill plug dipstick and  
check the lubricant level. Lubricant should  
be kept at the full mark on the dipstick.  
The correct transmission lubricant to use is  
Polaris Premium Synthetic Gearcase Lubri-  
cant (PN 2871478).  
146  
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MAINTENANCE  
Transmission Oil Changing Procedure  
1. Remove fill plug/dipstick.  
2. Remove transmission drain plug and drain the oil. Catch and discard used oilprop-  
erly.  
3. Clean and reinstall the drain plug.  
4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle)  
to full mark on the fill plug/dipstick.  
5. Check for leaks.  
147  
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MAINTENANCE  
Operating your ATV with worn tires, improperly inflated tires, non-standard tires  
or improperly installed tires will affect vehicle handling which could cause an  
accident resulting in serious injury or death.  
Follow the safeguards listed below to prevent this type of situation.  
148  
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MAINTENANCE  
Important Safeguards  
Maintain proper tire pressure according to charts below. Improper tire inflation may  
affect ATV maneuverability.  
Do not use improper tires. The use of non-standard size or type tires may affect ATV  
handling.  
Make certain the wheels are installed properly. If wheels are improperly installed it  
could affect vehicle handling and tire wear.  
Wheel Removal Procedure  
1. Stop the engine, place the transmission in gear 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.  
149  
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MAINTENANCE  
Wheel Size  
PSI  
Wheel Nut  
Torque  
Scrambler 50 Front  
Rear  
16 x 8 - 7  
16 x 8 - 7  
18 x 7 - 7  
18 x 7 - 7  
19 x 7 - 8  
18 x 9.5 - 8  
2
2
2
2
2
2
22 ft. lbs  
22 ft. lbs  
22 ft. lbs  
22 ft. lbs  
22 ft. lbs  
22 ft. lbs  
Scrambler 90 Front  
Rear  
Sportsman 90 Front  
Rear  
150  
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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. Attach the wheel nuts and finger tight-  
en them.  
3. Lower the vehicle to the ground.  
4. Securely tighten the wheel nuts ac-  
cording to the chart found on page 130:  
151  
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MAINTENANCE  
Tire Inspection  
When replacing a tire always use original equip-  
ment size and type.  
1
Tire Tread Depth  
Always replace tires when tread depth is worn  
to 1/8″ (.3 cm) (1) or less.  
152  
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MAINTENANCE  
Drive Chain Inspection and Adjustment  
Polaris ATV drive chains are equipped with O-ring sealed permanently greased  
pins and rollers. However, it is still necessary to lubricate the outer surfaces of the  
roller.  
Never wash the chain with a high pressure washer or gasoline. Damage to the  
O-rings will result, causing premature wear and drive chain failure.  
Regularly lubricate the drive chain with SAE 80-90 lube or an approved O-ring  
chain spray lube.  
Indicates a potential hazard which could  
result in severe injury or death.  
153  
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MAINTENANCE  
Drive Chain Inspection and Adjustment (Cont.)  
The adjuster stud must be held secure when tightening jam nuts or the stud  
may break.  
154  
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MAINTENANCE  
Rear Drive Chain Slack Adjustment  
Never adjust or operate the vehicle with the rear drive chain too loose or too  
tight as severe damage to the transmission and drive components can result.  
The normal  
chain slack  
A
should be kept  
between .40″ -  
1
.80″ ⟨10-20 mm)  
(A).  
155  
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MAINTENANCE  
Adjustment Procedure  
1. Loosen 4 rear housing mount bolts (A).  
2. Tighten chain adjuster (B) to reduce  
slack to recommended setting. (.4″ - .8″  
/ 10 mm - 20 mm)  
3. Tighten jam nuts on chain adjuster.  
4. Tighten the four rear housing mount  
bolts.  
A
B
156  
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MAINTENANCE  
Brakelight Lamp Replacement  
If the brakelight does not work the lamp may need to  
be replaced.  
1. From the rear of the brake light remove two  
screws (A)holding lens cover in place and remove  
lens cover (B).  
C
B
2. Remove lamp (C) and replace it with recom-  
mended lamp.  
A
3. Test the brakelight to see that it’s working.  
4. Reinstall the lens cover removed in step 1.  
157  
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MAINTENANCE  
Cleaning Your ATV  
Keeping your ATV clean will not only improve its appearance but it can also ex-  
tend the life of various components. With a few precautions, your ATV can be  
cleaned much like an automobile.  
Washing  
If a high pressure type car wash system is used, extreme care must be taken to  
avoid water damage to the wheel bearings, transmission seals, body panels,  
brakes and warning labels. Many expensive repair bills can result from using high  
pressure detergent systems.  
NOTE: If a high pressure car wash is used, grease all zerk fittings immediately  
after washing. Also run the vehicle to evaporate any water that might have en-  
tered the engine or exhaust system.  
158  
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MAINTENANCE  
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 labels are damaged, contact  
your a Polaris dealer for free replacement.  
Waxing  
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.  
Certain products, including insect repellants and chemicals, will damage plas-  
tic surfaces. Care must be taken when using these products near plastic sur-  
faces.  
159  
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MAINTENANCE  
Transporting  
Whenever the ATV is to be transported the following measures should be taken.  
1. Turn the fuel valve to off.  
2. Be certain the fuel cap, oil cap, and seat are installed correctly.  
3. Always tie the frame of the ATV to the transporting unit securely using suitable  
straps or rope.  
4. Always lock the parking brake.  
160  
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MAINTENANCE  
Carburetor Adjustments  
If the vehicle is to be operated at various altitudes and temperatures, certain ad-  
justments can be made to improve its operation and driveability. Above 6000 feet  
(1800 m) the engine air/fuel mixture becomes overly rich. An engine loses  
approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation.  
Although this power cannot be regained, changes to the carburetor and drive sys-  
tem can be made to allow efficient operation. These changes include:  
1. Carburetor re-jetting to compensate for altitude and/or temperature changes.  
2. Transmission convertor modification to adjust for engine horsepower loss during  
high altitude operation. Contact your dealer.  
3. On 2 cycle models, air screw adjustments can be made to compensate for temper-  
ature changes and/or changes in altitude.  
NOTE: Contact your dealer for altitude adjustments. They have the training and  
special tools required to perform all necessary modifications for you.  
161  
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SPECIFICATIONS  
Specifications - Scrambler 50  
Rider Capacity  
Displacement  
Cooling  
1
49cc  
Fan Cooled  
2-Stroke  
Engine type  
Lubrication  
Oil Injected  
1.1 quarts (1 liter)  
1.3 gallons (5 liters)  
Oil Capacity  
Fuel Capacity  
Starting  
Electric with kick-start backup  
Transmission  
Front Suspension  
Rear Suspension  
Automatic CVT  
A-Arm with 2″ (5 cm) of travel  
Spring over shock with 2 ″ (5 cm) of travel  
162  
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SPECIFICATIONS  
Specifications - Scrambler 50  
Drum  
Front/Rear Brakes  
Parking Brake  
Mechanical Lock  
Front and Rear Tires / PSI  
Turning Radius  
Wheel Base  
Dry Weight  
Length  
16 x 8-7 (2psi)  
74.8″ (190 cm)  
35.4″ (90 cm)  
211.6 lbs (96 kgs)  
54.6″ (138.7 cm)  
34″ (86.3 cm)  
34.7″ (88.2 cm)  
Standard  
Width  
Height  
Brake Light  
Low Oil Light  
Standard  
163  
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SPECIFICATIONS  
Specifications - Scrambler 90  
Rider Capacity  
Displacement  
Cooling  
1
89cc  
Fan Cooled  
2-Stroke  
Engine type  
Lubrication  
Oil Injected  
1.1 quarts (1 liter)  
1.3 gallons (5 liters)  
Oil Capacity  
Fuel Capacity  
Starting  
Electric with kick-start backup  
Transmission  
Front Suspension  
Rear Suspension  
Automatic CVT  
A-arm with 2″ (5 cm) of travel  
Spring over shock with 2″ (5 cm) of travel  
164  
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SPECIFICATIONS  
Specifications - Scrambler 90  
Drum  
Front/Rear Brakes  
Parking Brake  
Mechanical Lock  
Front and Rear Tires / PSI  
Turning Radius  
Wheel Base  
Dry Weight  
Length  
18 x 7 - 7 (2psi)  
98.4″ (250 cm)  
35.4″ (90 cm)  
233.7 lbs (106 kgs)  
56.1″ (142.4 cm)  
34″ (86.3 cm)  
36.1″ (91.8 cm)  
Standard  
Width  
Height  
Brake Light  
Low Oil Light  
Standard  
165  
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SPECIFICATIONS  
Specifications - Sportsman 90  
Rider Capacity  
Displacement  
Cooling  
1
89cc  
Fan Cooled  
2-Stroke  
Oil Injected  
1.1 qts. (1 ltr)  
1.3 ga. (5 ltr)  
Engine type  
Lubrication  
Oil Capacity  
Fuel Capacity  
Starting  
Electric with kick-start backup  
Transmission  
Front Suspension  
Rear Suspension  
Automatic CVT  
A-arm with 2 in / 5 cm of travel  
Spring over shock with 2 in / 5 cm of travel  
166  
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SPECIFICATIONS  
Specifications - Sportsman 90  
Drum  
Front/Rear Brakes  
Parking Brake  
Front Tires / PSI  
Rear Tires / PSI  
Wheel Base  
Turning Radius  
Dry Weight  
Mechanical Lock  
19 x 7 - 8 (2 psi)  
18 x 9.5 - 8 (2 psi)  
37.8″ (96 cm)  
98.4″ (250 cm)  
238.1 lbs (108 kgs)  
57.6 ″ (146.3 cm)  
34.4″ (87.4 cm)  
36.6″ (93 cm)  
Length  
Width  
Height  
Brake Light  
Standard  
167  
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SPECIFICATIONS  
Specifications - Sportsman 90  
Standard  
Low Oil Light  
Front Rack Capacity  
Rear Rack Capacity  
10 lb (4.5 kgs)  
20 lb (9 kgs)  
Accessories  
There are a wide range of Polaris Accessories available for ATVs. Contact your  
Polaris dealer to find out about the accessories available for your machine.  
168  
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WIRING DIAGRAM  
169  
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WIRING DIAGRAM  
170  
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TROUBLESHOOTING  
Procedures  
The following information is provided to help you identify probable causes for  
questions you may have about the operation of your ATV. See your Polaris dealer  
with any additional questions you may have.  
ENGINE CRANKS BUT FAILS TO START  
No Fuel  
Water in Fuel  
Drain System  
Spark Plug  
No Spark to  
Spark Plug  
Fuel Valve Off  
Clogged Fuel  
Valve or filter  
Contact Your  
Dealer  
171  
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TROUBLESHOOTING  
ENGINE STOPS OR LOSES POWER  
Engine  
Overheated  
Spark Plug  
Fouled  
No Fuel  
Clean Radiator  
screen and  
Radiator Core  
(liquid cooled  
models)  
Turn Fuel  
Air Filter  
Clogged  
Valve to “Res”  
Fuel Vent  
Line Kinked  
or Plugged  
Electronic  
Throttle Control  
Malfunction  
Clean Engine  
Exterior  
Water in Fuel  
Contact Your  
Dealer  
Contact Your  
Dealer  
172  
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WARRANTY  
LIMITED WARRANTY  
Polaris Industries 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 war-  
ranty on the final drive chain for failure due to defects. This warranty covers the parts  
and labor charges for repair or replacement of defective parts which are covered by  
this warranty. This warranty begins on the date of purchase. This warranty is transfer-  
rable to another consumer during the warranty period through a Polaris dealer. There  
is a charge of $35.00 payable to Polaris Industries Inc.  
173  
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WARRANTY  
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 PURCHASER 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  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. 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. Purchasing a machine in the crate or without proper dealer  
set--up will void your warranty coverage.  
174  
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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 warranty 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 warranty 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.  
175  
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WARRANTY  
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 warran-  
ty shall be, at Polaris’ exclusive option, repair or replacement of any defective materi-  
als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY  
ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FORBREACH OFTHIS  
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-  
DENTAL, CONSEQUENTIAL 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.  
176  
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WARRANTY  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED  
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUR-  
POSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PE-  
RIOD. 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.  
HOW TO OBTAIN WARRANTY SERVICE  
If your ATV requires warranty service, you must take it to a Polaris dealer authorized to  
repairPolaris 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 youroriginal selling dealer; however, you may use any Polaris Servicing Deal-  
er to perform warranty service.  
177  
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WARRANTY  
Please work with your dealer to resolve any warranty issues. Should your dealer re-  
quire any additional assistance they will contact the appropriate person at Polaris.  
This warranty gives you specific legal rights, and you may also have other rights  
which vary from state to state.  
If any of the above terms are void because of state or federal law, all other warranty  
terms will remain in effect.  
Engine Oil  
1. Always use Polaris engine oil.  
2. Neversubstitute ormix oilbrands as serious engine damage and voiding of warran-  
ty can result.  
178  
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INDEX  
Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65  
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Gas Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R6  
GENERAL SAFETY AND  
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . 132  
BATTERY INSTALLATION . . . . . . . . . . . . . . 110  
BATTERY MAINTENANCE . . . . . . . . . . . . . . 106  
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . 109  
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . 138  
Brake Freeplay Adjustment . . . . . . . . . . . . . . . 140  
Brake Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . R7  
BRAKE PARKING . . . . . . . . . . . . . . . . . . . . . . 58  
Brakelight Lamp Replacement . . . . . . . . . . . . . 157  
BRAKES, FRONT . . . . . . . . . . . . . . . . . . . . . . . 57  
BRAKES, REAR . . . . . . . . . . . . . . . . . . . . . . . . 57  
Break In Period . . . . . . . . . . . . . . . . . . . . . . . 74-76  
CAMBER AND CASTER . . . . . . . . . . . . . . . . 134  
CARBURETOR ADJUSTMENTS . . . . . . . . . . 161  
CARRYING LOADS . . . . . . . . . . . . . . . . . . 77-80  
Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . 155  
CLEANING YOUR ATV . . . . . . . . . . . . . . . . . 158  
Control and Parts Functions . . . . . . . . . . . . . 49-69  
CROSSING STREAMS . . . . . . . . . . . . . . . . . . . 98  
CYLINDER HEAD TORQUE . . . . . . . . . . . . . 145  
DAILY PRE-RIDE INSPECTION . . 20-21, 81-83  
Drive Chain Adjustment . . . . . . . . . . . . . . 153-154  
ENGINE ELECTRICAL SWITCHES . . . . . . . . 49  
Engine Start Button . . . . . . . . . . . . . . . . . . . . . . . 51  
Engine Stop Switch . . . . . . . . . . . . . . . . . . . R4, 50  
Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . R7  
DESCRIPTION OF LABELS . . . . . . . . 5-18  
HANDLEBAR ADJUSTMENT . . . . . . . . . . . . 128  
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . R8  
INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . 56  
Kick Starter . . . . . . . . . . . . . . . . . . . . . . . . . R5, 69  
KNOW YOUR MACHINE . . . . . . . . . . . R2-R11  
Load Capacity . . . . . . . . . . . . . . . . . . . . . . . . 77-80  
LUBRICANT, 2 Cycle . . . . . . . . . . . . . . . . . . . . 67  
LUBRICATION RECOMMENDATIONS 122-123  
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49  
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 106-111  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . 115-161  
MAINTENANCE RECORD . . . . . . . . . . . . . . 126  
MAINTENANCE SCHEDULE . . . . . . . . 115-118  
MAKING TURNS . . . . . . . . . . . . . . . . . . . . . . . 86  
NOISE CONTROL SYSTEM . . . . . . . . . . 112-114  
OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 63  
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66  
OPERATION WARNINGS . . . . . . . . . . . . . . 19-46  
PARKING ON AN INCLINE . . . . . . . . . . . . . . 102  
179  
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INDEX  
Pre Operation Check . . . . . . . . . . . . . . . . R12-R15  
PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . 62, 104  
Rear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . R7  
REAR SPRING ADJUSTMENT . . . . . . . . . . . 131  
RIDER’S SECTION . . . . . . . . . . . . . . . . . . . . . R1  
RIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . 84-103  
Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . 72-73  
RIDING ON SLIPPERY SURFACES . . . . . . . . . 88  
SAFETY WARNING AND  
Toe Alignment . . . . . . . . . . . . . . . . . . . . . 136-137  
TOOL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115  
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 130  
TRAIL OBSTACLES . . . . . . . . . . . . . . . . . . . . 100  
TRANSMISSION LUBRICATION . . . . . . . . . 146  
TRANSMISSION  
OIL CHANGING PROCEDURE . . . . . . . 147  
TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . 160  
TRAVELING DOWNHILL . . . . . . . . . . . . . . . . 94  
TRAVELING UPHILL . . . . . . . . . . . . . . . . . . . . 90  
TROUBLESHOOTING . . . . . . . . . . . . . . 171-172  
TURNING AROUND ON A HILL . . . . . . . . . . 96  
UNDERSTANDING WARNINGS . . . . . . . . . . 1-4  
Understanding Warnings . . . . . . . . . . . . R16-R20  
VEHICLE IDENTIFICATION NUMBERS . 47-48  
WARRANTY . . . . . . . . . . . . . . . . . . . . . . 173-178  
WHEEL INSTALLATION . . . . . . . . . . . . 149-151  
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . 150  
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . 149  
WIRING DIAGRAM . . . . . . . . . . . . . . . . 169-170  
OPERATION DECALS . . . . . . . . . . . . . . . 10  
SIDEHILLING . . . . . . . . . . . . . . . . . . . . . . . . . . 92  
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . 142  
SPECIFICATIONS . . . . . . . . . . . . . . . . . . 162-168  
STARTING A COLD ENGINE . . . . . . . . . . . . . 70  
Starting the Engine . . . . . . . . . . . . . . . . . . . . 70-71  
STEERING INSPECTION . . . . . . . . . . . . . . . . 134  
Tether Strap . . . . . . . . . . . . . . . . . . . . . . . . . . . R9  
Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . R4, 53  
Throttle Cable Adjustment . . . . . . . . . . . . 135, 141  
THROTTLE LEVER . . . . . . . . . . . . . . . . . . . . . 54  
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . 152  
180  
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