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Polaris Outlaw 110 2022, Owner'S Manual, Page: 140 / 211

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Polaris Outlaw 110 2022 Owner'S Manual Download Page 140

DRIVE CHAIN SLACK

1.  Check the amount of chain slack by moving 

the vehicle slightly forward to gain slack at the 
top side of the chain.

2.  Collapse the suspension with an adjustable 

(buckle type) trailer tiedown strap. Fasten the 
strap around the axle and rear bumper tube.

3.  Tighten the strap until a straight line can be 

drawn from the rear axle to the gearcase 
output shaft intersecting the swing arm pivot. 
This establishes the tightest chain position.

4.  Pull down on the chain tensioner 

q 

to move it 

out of the way, then measure chain slack. It 
should have 1/4"-1/2" (6-12 mm) deflection.

5.  If the chain needs adjustment, use the 

procedure cited below.

138

MAINTENANCE

Summary of Contents for Outlaw 110 2022

Page 1: ...and Safety Sportsman 110 Outlaw 110 WARNING Read this manual carefully It contains important safety information Adult supervision is required for children under 16 years of age Operation is prohibited...

Page 2: ...le in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle WARNING Read understand and f...

Page 3: ...2022 Owner s Manual Outlaw 110 Sportsman 110...

Page 4: ...regarding your Polaris vehicle This safety video can also be found at http www polaris com en us rider support safety If you are on the homepage of the Polaris website click on the Rider Community he...

Page 5: ...ue to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictio...

Page 6: ......

Page 7: ...ction 9 Safety 15 Young Riders Section 53 Features and Controls 65 Operation 75 Emission Control Systems 97 Maintenance 103 Specifications 163 Polaris Products 171 Troubleshooting 175 Warranty 181 Mai...

Page 8: ...6...

Page 9: ...a child under the age of 16 to operate an ATV without adult supervision Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Permit continu...

Page 10: ...ead and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents supervising adult to explain anything you don t understand...

Page 11: ...s and symbols are used Become familiar with their meanings before reading the manual DANGER DANGER indicates a hazardous situation that if not avoided will result in death to the operator bystanders o...

Page 12: ...result in death to the operator bystanders or person s inspecting or servicing the vehicle NOTICE NOTICE provides key information by clarifying instructions IMPORTANT IMPORTANT provides key reminders...

Page 13: ...The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard 11 INTRODUCTION...

Page 14: ...es provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a POLARIS key blank using your key number and mating it with one of your existing keys...

Page 15: ...Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course See page 33 for details on how to access a training course For your child s safety be sure your chi...

Page 16: ...DECLARATION OF CONFORMITY 14 INTRODUCTION...

Page 17: ...ty DVD provided with your vehicle Be sure to read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your child s safety Be sure to explain to yo...

Page 18: ...warning and instruction labels before operating the vehicle Never allow a guest to operate this vehicle until the guest has read this manual and all product labels AGE RESTRICTIONS Operation is prohib...

Page 19: ...rformed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing EXPOS...

Page 20: ...intenance procedures and schedules described in this owner s manual PROTECTIVE APPAREL Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of...

Page 21: ...eaction time balance and perception Never consume alcohol or drugs before or while operating or riding in this vehicle CARRYING A PASSENGER Carrying a passenger greatly reduces the operator s ability...

Page 22: ...ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops OPERATING ON PUBLIC ROADS Operating this ATV on public streets roads or highw...

Page 23: ...ty operating conditions and your riding experience TURNING IMPROPERLY Turning improperly could cause loss of traction loss of control accident or rollover Always follow proper procedures for turning a...

Page 24: ...the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the...

Page 25: ...age 88 Always follow proper procedures for traveling down hills as described in the owner s manual Always check the terrain carefully before descending a hill Shift your weight rearward Never travel d...

Page 26: ...roper procedures for climbing hills as described in the owner s manual See page 24 OPERATING ON STEEP HILLS Operating on excessively steep hills could cause an overturn Never operate on hills too stee...

Page 27: ...ed in the owner s manual See the Turning Around on a Hill section for details STALLING WHILE CLIMBING A HILL Stalling rolling backwards or improperly dismounting while climbing a hill could cause an o...

Page 28: ...ual See the Turning Around on a Hill section for details OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfam...

Page 29: ...extra caution on rough slippery or loose terrain OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating...

Page 30: ...properly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unav...

Page 31: ...erating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water OPERATING THROUGH DEEP WATER...

Page 32: ...ving The friction will help dry out the pads IMPROPER CARGO LOADING Overloading the ATV or carrying towing cargo may cause changes in handling which could cause loss of control or an accident Never ha...

Page 33: ...AUTHORIZED USE OF THE ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is...

Page 34: ...exhaust system Use caution when traveling through tall grass especially dry grass and when traveling through muddy conditions Always inspect the underside of the vehicle and areas near the exhaust sys...

Page 35: ...ion with your child young operators on a regular basis Do not allow other children to ride this ATV unless they have read the manual seen the instructional video or DVD and taken and completed an appr...

Page 36: ...or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death Use only POLARIS approved accessories to modify...

Page 37: ...SAFE RIDING GEAR Always wear the right kind of clothing and safety gear when riding your ATV q A helmet w Eye protection e Long sleeve shirt r Gloves t Long pants y Over the ankle boots 35 SAFETY...

Page 38: ...ortation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country...

Page 39: ...nerated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area The condition occurs most frequently when a vehicle is being operated in high ambient temperature...

Page 40: ...the labels depicted in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or...

Page 41: ...ocated on the rear of the right front fender WARNING Operation of this ATV by children under age 10 increases the risk of severe injury or death Adult supervision required for children under age 16 NE...

Page 42: ...e 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...

Page 43: ...ING Never operate this ATV on HILLS steeper than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at lo...

Page 44: ...on the exterior of the left rear fender WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 3 0 psi 20...

Page 45: ...s located on the left rear fender WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 3 0 psi 20 7 kPa...

Page 46: ...NGER WARNING WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH The No Passenger Warning labels are located as follows Sportsman q Outlaw w 44...

Page 47: ...d topside of the forward rack The rear rack warning w is located on the back facing edge of the rear rack WARNING DO NOT TOW Vehicle damage or tipover may result causing severe injury or death Maximum...

Page 48: ...arts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause...

Page 49: ...INTERNATIONAL LABELS CLUTCH COVER ALERT Read the owner s manual Keep limbs away from moving parts The clutch cover alert label is located on the vehicle s clutch cover Part number 7181427 47 SAFETY...

Page 50: ...than 15 degrees To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prev...

Page 51: ...e this ATV NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Improper tire pressure or overloading can cause loss of control Loss of control can resu...

Page 52: ...ate this ATV NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH Improper tire pressure or overloading can cause loss of control Loss of control can re...

Page 53: ...OT TOW Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 lb 7 kg Rear 30 lb 14 kg The rack alert is located on the back facing edge of the rear rack Part...

Page 54: ...52...

Page 55: ...maximum rider weight capacity is exceeded See vehicle specifications on page for your ATV s weight capacity YOUNG RIDERS Before riding your new POLARIS ATV there are important things you need to know...

Page 56: ...the engine off quickly The button must be in the up position before you can start the engine again w Horn Button Press the horn button to sound the horn e Throttle Control Press the throttle lever wi...

Page 57: ...Make sure it is closed tightly WARNING Always have an adult put gas in your ATV Never try to do it yourself y Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fen...

Page 58: ...vers at the same time The left lever u controls the rear brake The right lever o controls the front brake WARNING Always squeeze both brake levers simultaneously or you could lose control of the ATV a...

Page 59: ...Tether Strap and Switch The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switc...

Page 60: ...er Switch s Sportsman Ignition Switch d Tether Switch f Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key...

Page 61: ...lowly or stays close to the handlebar the ATV has a sticky throttle This means that something is wrong or broken and must be fixed before you can ride your ATV safely WARNING Never start the engine if...

Page 62: ...re seat is secure If you used the storage area under the seat make sure the seat is secured in place 5 Check the oil Have an adult check the engine oil level when the engine is cold When the engine ha...

Page 63: ...when we ride NOTE The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to drive safely WARNING Always follow the safe riding rules found in the next...

Page 64: ...moving parts Wear long sleeves and long pants to protect arms and legs from injury RULES TO REMEMBER Always attach the tether strap to your right wrist and to the ATV before riding Always know where...

Page 65: ...ks or trains that may be coming toward you Never ride at night Your ATV is not equipped with lights that are safe for driving in the dark Learn where lakes rivers ponds and ditches are located in your...

Page 66: ...Respect your ATV Respect your environment You will earn the respect of everyone Enjoy riding your new POLARIS ATV 64 YOUNG RIDERS SECTION...

Page 67: ...stop switch q is down OFF position the engine will not start or run and all electrical power is cut off to the vehicle In case of stuck throttle emergency or to stop the engine quickly push stop swit...

Page 68: ...dent if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation The throttle release switch l...

Page 69: ...pped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the lever engin...

Page 70: ...adjustment is important to assure proper transmission function See your dealer or other qualified person if you experience any shifting problems SHIFT PATTERN F Forward Gear N Neutral R Reverse NOTICE...

Page 71: ...right lever controls the front brakes w WARNING Applying only one brake could cause loss of control and result in serious injury or death Always apply both brakes at the same time PARKING BRAKE Alway...

Page 72: ...brake squeeze and release the brake lever The brake will release automatically WARNING Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or deat...

Page 73: ...ighways INDICATOR DESCRIPTION Neutral q Transmission is in neutral Reverse w Transmission is in reverse Low Fuel e The ATV can operate 7 10 miles 11 16 km before the tank is completely empty Check Eng...

Page 74: ...Outlaw Sportsman 72 FEATURES AND CONTROLS...

Page 75: ...ndlebars Use unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 percent such as E 85 fuel Refer...

Page 76: ...74...

Page 77: ...nual VEHICLE BREAK IN PERIOD The break in period for your new Polaris vehicle is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single...

Page 78: ...andling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 77 NOTICE Ex...

Page 79: ...sure it s in safe operating condition ITEM REMARKS PAGE Brake system lever travel Ensure proper operation See page 131 Front suspension Inspect lubricate if necessary See page 115 Rear suspension Insp...

Page 80: ...ensure tightness Fuel and oil Ensure proper levels See page 38 for label locations and page 73 for fuel system Grass and debris Remove grass leaves foreign matter and other flammable material or debri...

Page 81: ...eration See page 146 Brake light Ensure proper operation See page 146 Drive Chain Check condition and slack refer to drive chain adjustment See page 137 Loose or Damaged components Visually inspect fo...

Page 82: ...e include the weight of the operator accessories and loads on the racks if equipped The combined weight of these items must not exceed the maximum weight capacity 6 Ride this vehicle only in areas per...

Page 83: ...r accident have a qualified service dealer inspect the entire machine for possible damage 11 Never operate the vehicle on a frozen body of water 12 Do not touch hot exhaust system components Always ke...

Page 84: ...several minutes before operating the vehicle Follow the steps below for proper engine start procedure 1 Shift the transmission to neutral 2 Lock the parking brake 3 Sit on the vehicle Attach the teth...

Page 85: ...when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts STOPPING THE ENGINE 1 Release the throttle compl...

Page 86: ...s 2 Shift the transmission to neutral 3 Start the engine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Squeeze the left brake lever 6 Shift the transmission to...

Page 87: ...t slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balan...

Page 88: ...n operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6...

Page 89: ...4 Never climb hills with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill 7 Proceed at a steady rate of speed and throttle opening Opening the thrott...

Page 90: ...1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keeping your feet on the footrests 3 If the vehicle begins to slide or tip quickly turn the front wheel downhill if p...

Page 91: ...s at the same time and very slightly to aid in slowing TURNING AROUND ON A HILL If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 1 Stop the vehicle...

Page 92: ...wly release the brake allowing the ATV to roll around to your right until it s pointing across the hill or slightly downward 7 Lock the parking brake and remount the ATV from the uphill side keeping b...

Page 93: ...Avoid parking on a hill or incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown in t...

Page 94: ...perate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause ski...

Page 95: ...ating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obstacles such as rocks or fallen trees DRIVING THROUGH WATER Your ATV can safely operate th...

Page 96: ...r fast flowing water 4 After driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes...

Page 97: ...rturns in water or if the engine stops during or after operating in water service is required before starting the engine Your POLARIS dealer can provide this service If it s impossible to bring the ve...

Page 98: ...isted in the specifications section beginning on page Secure all cargo before driving Loose cargo may move or shift which could cause loss of control or a tipover Use suitable tie downs or rope to sec...

Page 99: ...ments 40 CFR 205 and local noise level requirements OPERATION ON PUBLIC LANDS IN THE U S A Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 51...

Page 100: ...ormance and are not adjustable The emissions label is located on the inside of the lower left frame tube below driver s foot area ELECTROMAGNETIC INTERFERENCE This spark ignition system complies with...

Page 101: ...99 EMISSION CONTROL SYSTEMS...

Page 102: ...machinery is measured per EN 15997 NOISE OUTLAW 110 SPORTSMAN 110 A Weighted Sound Pressure Level at Rider s Ear 82 dB A 90 dB A Peak C Weighted Sound Pressure Level at Rider s Ear 93 dB C 98 dB C A...

Page 103: ...VIBRATIONS OUTLAW 110 SPORTSMAN 110 Weighted Hand Arm Vibration Level 3 0 m s2 2 9 m s2 Weighted Seat Vibration Level 1 6 m s2 1 2 m s2 101 EMISSION CONTROL SYSTEMS...

Page 104: ...102...

Page 105: ...art supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law Owners are responsible for...

Page 106: ...nce intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and se...

Page 107: ...zed Polaris dealer or other qualified person perform these services SEVERE USE DEFINITION Frequent immersion in mud water or sand Frequent or prolonged operation in dusty environments Short trip cold...

Page 108: ...o rise discontinue use and determine the cause Your dealer can assist MAINTENANCE CHART WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serio...

Page 109: ...aily Check each day before driving the vehicle Make adjustments as needed See the Pre Ride Checklist Front Suspension Rear Suspension Daily Check each day before driving the vehicle Make adjustments a...

Page 110: ...eners Frame Fasteners Engine Oil Level Daily Check each day before driving the vehicle Make adjustments as needed See the Pre Ride Checklist Air Filter Pre Filter Main Element Daily Inspect clean ofte...

Page 111: ...eration apply dielectric grease if replacing Drive Chain Daily Inspect daily adjust as needed check often if driving in wet conditions CVT Housing if equipped Daily Drain water as needed check often i...

Page 112: ...reeplay 10 Monthly 100 160 Inspect periodically Spark Plug 10 Monthly 100 160 Clean check condition adjust gap replace as needed Fuel System 20 Monthly Inspect cycle key to pressurize fuel pump check...

Page 113: ...ssion Oil 40 12 Mo 400 640 Drain and change oil XU Oil Pre Filter Screen 40 12 Mo 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours XU General Lubrication 5...

Page 114: ...ble Release Switch 50 6 Mo 500 800 Inspect adjust lubricate replace if necessary Throttle Body Intake Duct 50 6 Mo 500 800 Inspect duct for proper sealing air leaks D Drive Belt 50 6 Mo 500 800 See yo...

Page 115: ...r 100 12 Mo 600 1000 Cycle key to pressurize fuel pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years XU Engine Mounts 100 12 Mo 1000 1600 Inspect Exhaust Muff...

Page 116: ...security apply dielectric grease to connectors subjected to water mud etc D Clutches Drive Driven 100 12 Mo 1000 1600 Inspect clean replace worn parts D Front Wheel Bearings 100 12 Mo 1000 1600 Inspec...

Page 117: ...Transmission Fluid See page 120 Drive Chain POLARIS Chain Lube or SAE 80 90 See page 137 Front Arm Suspension A Arm Pivots POLARIS All Season Grease or grease conforming to NLGI No 2 Inspect tighten f...

Page 118: ...q Grease Points 116 MAINTENANCE...

Page 119: ...ive oil See page 171 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix...

Page 120: ...etween checks in cool weather driving may indicate contaminants such as gas or moisture collecting in the crankcase If oil level is over the full safe mark change oil immediately w Safe Range e Add Oi...

Page 121: ...filter screen with solvent to remove debris Allow the screen to air dry 8 Clean the pre filter plug Install a new sealing washer on the plug The sealing surfaces on the plug and crankcase should be c...

Page 122: ...Polaris recommends the use of AGL Gearcase Lubricant Transmission Fluid for this vehicle FLUID CHECK The fill plug q is located on the rear of the gearcase The drain plug w is located on the bottom o...

Page 123: ...e the drain plug Allow the fluid to drain completely 5 Clean the drain plug 6 Reinstall the drain plug with a new o ring Torque to 14 ft lbs 19 Nm 7 Add recommended oil Maintain oil level at the botto...

Page 124: ...if the machine is not thoroughly inspected Take the vehicle in for service before starting the engine Your POLARIS dealer can provide this service If it s impossible to take your vehicle to a dealer...

Page 125: ...sted into the transmission follow the procedure on page 125 for drying the CVT SPARK PLUGS SPARK PLUG GAP TORQUE Refer to the specifications section beginning on page for spark plug and gap specificat...

Page 126: ...ouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil us...

Page 127: ...ibration and additional loads on components Always follow all recommended maintenance procedures See your POLARIS dealer or other qualified person for service and repair assistance This CVTsystem is i...

Page 128: ...clutches Do not hold the throttle wide open for more than 10 seconds 4 Allow the engine RPM to settle to idle speed 5 Test for belt slippage If the belt slips repeat the process 6 Your vehicle requir...

Page 129: ...Exhaust contains poisonous carbon monoxide gas To remove accumulated carbon clean the spark arrester at the intervals recommended in the Periodic Maintenance Chart section 1 Remove the six bolts and r...

Page 130: ...q Arrester Screen 128 MAINTENANCE...

Page 131: ...ust any speed limiting devices This vehicle has an adjustable speed control system that controls engine RPM and speed of the vehicle The speed limiting device may be adjusted by supervising adults whe...

Page 132: ...after adjusting THROTTLE CABLE ADJUSTMENT Always check the throttle for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If ad...

Page 133: ...ance Chart beginning on page 103 If the freeplay isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specifications Front Brake Rear Brake 08 12 2 3 mm 08 12 2...

Page 134: ...e adjuster nut one full turn 6 While rotating the right front wheel tighten the lower front brake adjuster nut q on the right hand control 7 When you begin to feel a slight drag in wheel rotation loos...

Page 135: ...ating the rear wheels tighten the rear brake wing nut q at the rear brake drum 5 When you begin to feel a slight drag in wheel rotation loosen the wing nut one full turn 6 Verify that the left hand br...

Page 136: ...determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table below Always service the brakes when there is no longer...

Page 137: ...may use a long straightedge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the...

Page 138: ...cle which could result in an accident Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments The front and rear shock absorber springs are ad...

Page 139: ...171 for the part numbers of Polaris products NOTICE Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t use a high pressure washer or...

Page 140: ...p around the axle and rear bumper tube 3 Tighten the strap until a straight line can be drawn from the rear axle to the gearcase output shaft intersecting the swing arm pivot This establishes the tigh...

Page 141: ...r lock nut 3 Turn the chain adjuster w clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nuts to 18 ft lbs 25 Nm Hold the adjuster stud securely while tightening the nut to avo...

Page 142: ...warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply a commercially available foam filter lubricant to the foam filter 5 Clean away any oil or sediments...

Page 143: ...q Clips w Cover e Foam Filter 141 MAINTENANCE...

Page 144: ...g of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment proc...

Page 145: ...n the four bolts 2 Adjust the handlebar to the desired height Be sure the handlebars do not hit the gas tank or any other part of the vehicle when turned fully to the left or right 3 Lightly tighten e...

Page 146: ...onally Cracking of the tread and sidewall rubber sometimes accompanied by carcass deformation is evidence of aging Old and aged tires must be checked by tire specialists to ascertain their suitability...

Page 147: ...he engine and lock the parking brake 2 Loosen the wheel bolts q slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel bolts and remove the...

Page 148: ...ion are critical component operations All service must be performed by your authorized Polaris dealer or other qualified service facility AXLE AND WHEEL NUTS Do not service axle nuts that have a cotte...

Page 149: ...not operate see your POLARIS dealer for service 8 Reinstall the rubber cover and reconnect the lights to the harness 9 Reinstall the front cover OUTLAW only INDICATOR LIGHTS 1 Remove the handlebar co...

Page 150: ...ING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When r...

Page 151: ...p 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Lift the battery out of the ATV BATTERY INSTALLATION AND CONNECTIONS Always install a fully cha...

Page 152: ...intaining long battery life The types of batteries are Lead Acid Conventional Dry Shipped Absorbed Glass Mat AGM Lead Acid Low Maintenance AGM Low Maintenance Refer to the examples below to identify t...

Page 153: ...LOW MAINTENANCE BATTERY The battery is activated when packaged Non removable cap s is are located on top of the battery Distilled water or electrolyte is NEVER added 151 MAINTENANCE...

Page 154: ...charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging The sealed battery is already filled with electrolyte and has been seale...

Page 155: ...r more than TWO WEEKS Polaris recommends using a BatteryMINDer 2012 AGM 2 AMP charger PN 2830438 which can be ordered through your dealer During charging place the charger outside of the vehicle and p...

Page 156: ...atteryMINDer 2012 AGM 2 AMP charger When using an automatic charger other than a BatteryMINDer 2012 AGM 2 AMP charger refer to the charger manufacturer s instructions for recharging If using a constan...

Page 157: ...east 20 hours Using AGM specific charger at standard amps specified on top of battery BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more remove the battery from the...

Page 158: ...vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dr...

Page 159: ...ean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish POLISHING It is recommended to use common household aerosol furnitu...

Page 160: ...the recommended fuel 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer or equivalent fuel treatments or stabilizers Follow the instructions on the container for the recommended amou...

Page 161: ...o specification See page 123 4 Apply dielectric grease to the inside of the spark plug cap Do not reinstall the cap onto the plug at this step 5 Turn the engine over several times Oil will be forced i...

Page 162: ...Chart beginning on page 106 STORAGE AREA COVERS 1 Make sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching t...

Page 163: ...fuel cap oil cap and seat NOTICE Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down...

Page 164: ...3 Wrap the front tie strap through the frame tubes not through the bumper tubes or attach a tie down hook around each of the tubes 4 Wrap the rear tie strap around the grab bar 162 MAINTENANCE...

Page 165: ...0 lbs 81 7 kg Dry Weight 278 lbs 126 kg Length Width Height 61 75 157 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Engine type 4 Stroke D...

Page 166: ...tion Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gallons 6 4 liters Fuel Reserve Capacity 23 gallons 86 liters Starting System Electric Fuel System Electronic fuel injection Throttle Body Siz...

Page 167: ...ain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel Front Rear Brakes Drum Parking Brake Mechanical Lock Front Tires 19 x 7 8 3 psi 20 7 kPa R...

Page 168: ...lb 131 kg Length Width Height 61 75 in 157 cm 36 75 in 93 cm 38 5 in 98 cm Wheel Base 41 5 in 105 cm Ground Clearance 4 in 10 cm at swing arm 7 7 in 19 5 cm at frame Engine type 4 Stroke Displacement...

Page 169: ...city 30 oz 900 mL Fuel Capacity 2 gal 7 7 L Fuel Reserve Capacity 0 22 gal 0 85 L Starting System Electric Fuel System Electronic fuel injection Throttle Body Size 22 mm Ignition System CDI Ignition T...

Page 170: ...arm with 5 in 12 7 cm of travel Rear Suspension Swing arm with 6 in 15 2 cm of travel Front Rack Capacity 15 lb 7 kg Rear Rack Capacity 30 lb 14 kg Front Rear Brakes Drum Parking Brake Mechanical Lock...

Page 171: ...POLARIS SPORTSMAN 110 Brake Light Standard Daytime Running Lights Standard 169 SPECIFICATIONS...

Page 172: ...170...

Page 173: ...INE LUBRICANT PART NUMBER DESCRIPTION 2870791 Fogging Oil 12 oz Aerosol 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 l 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 l...

Page 174: ...se Lubricant Transmission Fluid qt 95 l 2878069 AGL Full Synthetic Gearcase Lubricant Transmission Fluid gal 3 8 l 2872348 Chain Lube Aerosol GREASE PART NUMBER DESCRIPTION 2871322 All Season Grease 3...

Page 175: ...ADDITIVES MISCELLANEOUS PART NUMBER DESCRIPTION 2871326 Carbon Clean 173 POLARIS PRODUCTS...

Page 176: ...174...

Page 177: ...ons and tighten Loose solenoid connections Check all connections and tighten ENGINE TURNS OVER FAILS TO START POSSIBLE CAUSE SOLUTION Out of fuel Refuel cycle key to ON position three times for 5 seco...

Page 178: ...ogged Fuel Filter Your POLARIS dealer can assist Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure Your POLARIS dealer can assist ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION P...

Page 179: ...sist Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery volta...

Page 180: ...er can assist POSSIBLE LEAN FUEL CAUSE SOLUTION Low or contaminated fuel Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with...

Page 181: ...led or defective spark plug s Inspect clean and or replace spark plugs Worn or defective spark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or repl...

Page 182: ...TION Throttle release switch malfunction Your POLARIS dealer can assist Overheated engine Clean engine exterior Your POLARIS dealer can assist Other mechanical failure Your POLARIS dealer can assist 1...

Page 183: ...ted to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and beg...

Page 184: ...itial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty cover...

Page 185: ...unapproved components accessories or attachments use of unapproved software or calibration unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center T...

Page 186: ...components Batteries Light bulbs Sealed beam lamps Filters Lubricants Bushings Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components a...

Page 187: ...ation or personal time THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THI...

Page 188: ...TATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty...

Page 189: ...of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another country be sure to contact POLARIS Customer Assistanc...

Page 190: ...REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products t...

Page 191: ...d Warranty Please work with your dealer to resolve any warranty issues Dealership contacts can be found via this website if needed www polaris com en us contact Should your dealer require any addition...

Page 192: ...d of 500 hours of engine operation 3100 miles 5000 km of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100 cm3 emissions c...

Page 193: ...is emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts rel...

Page 194: ...gs Clamps Pressure Relief Valves Control Valves Control Solenoids Electronic Controls Vacuum Control Diaphragms Control Cables Control Linkages Purge Valves Vapor Hoses Liquid Vapor Separator Carbon C...

Page 195: ...IAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND...

Page 196: ...wner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no responsibility or by ac...

Page 197: ...ions and may void this limited emissions warranty offered by the manufacturer The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreatio...

Page 198: ...el tank fuel hoses carbon canister engine computer and Evaporative Emissions Control System parts listed in the U S A EPA Emissions Limited Warranty Also included may be hoses belts connectors and oth...

Page 199: ...ime not to exceed 30 days As an OHRV EVAP owner you should also be aware that Polaris may deny you warranty coverage if your OHRV EVAP or a part has failed due to abuse neglect improper maintenance or...

Page 200: ...French 1 800 268 6334 198 WARRANTY...

Page 201: ...MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 199 MAINTENANCE LOG...

Page 202: ...DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 200 MAINTENANCE LOG...

Page 203: ...DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 201 MAINTENANCE LOG...

Page 204: ...202...

Page 205: ...136 Carrying a Passenger 19 Clothing 37 Clutch Cover Warning 46 Constant Variable Transmission CVT System 125 Crankcase Emission Control System 98 Crossing Hillsides 25 Cylinder Head Torque 122 D Dayt...

Page 206: ...65 Engine Stops 179 Engine Turns Over Fails to Start 175 Equipment Modifications 34 Exhaust Emission Control System 98 Exported Products 188 Exposure to Exhaust 17 Eye Protection 36 F Failure to Inspe...

Page 207: ...Clutch Cover Alert 47 Proper Use Alert 48 Rack Alert Sportsman 51 J Jumps and Stunts 22 K Know Your ATV 53 L Lamp Light Replacement 146 Limited Warranty 181 Loss of Control 28 Lubrication Recommendat...

Page 208: ...struction 16 Operation on Public Lands in the U S A 97 Operation Warning 75 Outlaw 110 Specifications 163 P Parking Brake 69 Parking on a Hill or Incline 91 Periodic Maintenance 103 Severe Use Definit...

Page 209: ...157 T Tail Light Replacement 147 Throttle Cable Adjustment 130 Throttle Controls 66 Throttle Lever 67 Throttle Stop 129 Throttle System 129 Tire Pressure Load Warning Sportsman 43 Tire Tread Depth 144...

Page 210: ......

Page 211: ...seriously affect handling and control SEE FULL OWNER S MANUAL FOR PRODUCT AND SAFETY INFORMATION FOLLOW ALL INSTRUCTIONS AND WARNINGS Never operate without proper training or instruction at speeds to...

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