Polaris Sportsman 9921796 Owner'S Manual Download

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126

Maintenance

Speed Control System

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

youth models is restricted to

under

10 MPH for the 50cc models and

under

15 MPH for the

90cc models.

The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the

consumer's request, remove or adjust any speed limiting devices.

Your Polaris ATV has an adjustable throttle limiting screw. Speed limiting devices may be

adjusted/removed

only by consumers

when they determine that their child is capable of han-

dling the additional speed.
Per ANSI / SVIA-1-2001 (sec. 6.2) the

unrestricted

top speed is less than 15 MPH for the

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

Summary of Contents for Sportsman 9921796

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Page 3: ...er s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 4: ...1 Visit us at www polarisindustries com ...

Page 5: ...uality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is expre...

Page 6: ...ed in this owner s manual Help them also learn to show respect for our environment and for the rights of others while operating the ATV Never allow a child under the age of 16 to operate an ATV without adult supervision Chil dren differ in skills physical abilities and judgement Some children may not be able to oper ate an ATV safely Permit continued use only if you determine that your child has t...

Page 7: ...eed to read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others is the most important thing to think about at all times Never drive your ATV alone Always make sure an adul...

Page 8: ...Your ATV 40 Pre Ride Check 47 Riding Rules 50 Adult Section 55 Vehicle ID Numbers 56 Features and Controls 57 Operation 69 Emission Control Systems 96 Maintenance 98 Specifications 162 Polaris Products 166 Troubleshooting 168 Warranty 174 Maintenance Log 182 Index 186 ...

Page 9: ...ntial personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a...

Page 10: ... manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCoursesm Always follow the age guidelines for your vehicle Y 12 90cc models are...

Page 11: ...ages you and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm In addition you were provided with printed material and a video or DVD that instructs operators on safe operating procedures You should review this information with your child on a regular basis Do not allow other children to ride this ATV unless they have read the manual seen the instructional v...

Page 12: ...nrollment Express at 800 887 2887 or by visiting www atvsafety org Purchas ers of a used Polaris ATV will be charged for this training FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 ...

Page 13: ... or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be dis played...

Page 14: ...nal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of strong over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with knee pads and a jerse...

Page 15: ...urposes Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories may change the handling characteristics o...

Page 16: ...are provided for your child s safety Be sure to explain to your young driver that the hazards outlined in this section of the owner s manual MUST be avoided at all times See the RIDING RULES section and the OPERATION section of the owner s manual for proper operating procedures Operator Restrictions Age Restrictions This vehicle is for recreational use by young operators under adult supervision ON...

Page 17: ...rators should complete the ATV RiderCoursesm offered by Polaris through the SVIA 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 ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org Never permit a guest to operate the ATV unless the guest has read ...

Page 18: ...asoline 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 Turn the fuel valve off whenever the ATV is stored or parked See page 67 Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it r...

Page 19: ...intenance procedures and schedules described in the 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 an accident Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident Always wear an approved helmet that fits properly...

Page 20: ...e and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV ...

Page 21: ...Avoid operating the 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 highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to opera...

Page 22: ...nditions and your experience Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from 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 al...

Page 23: ... for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving ...

Page 24: ...rn Always follow proper procedures for climbing hills as described in the owner s manual See page 84 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 15 degrees 15 ...

Page 25: ...escribed in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 87 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible ...

Page 26: ...turn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 86 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 88 ...

Page 27: ...gradually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If the ATV begins rolling downhill Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to either side if pointed...

Page 28: ...ly rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain ...

Page 29: ...ntenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or perso...

Page 30: ...cording to approved instructions See your authorized Polaris ATV dealer for more information Operating Over Obstacles Improperly 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 unavoidable use extreme caution and always follow proper operating procedures as out...

Page 31: ... If it s unavoidable to enter water that exceeds the height of the footrests Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction...

Page 32: ...andling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes or steering The object may overturn or collide with other objects Never exceed the stated load capacity for this ATV ...

Page 33: ...V Operating a damaged ATV can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this veh...

Page 34: ... system Use caution when traveling through tall grass especially dry grass Always inspect the underside of the ATV after driving through tall grass weeds brush and other tall ground cover Promptly remove any grass or debris clinging to the vehicle Unauthorized 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 A...

Page 35: ... the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label Age Warning WARNING Operation of this ATV by children under the age of 12 increases the risk of severe injury or death Adult supervision required fo...

Page 36: ... 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 cont...

Page 37: ... ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175748 ...

Page 38: ... death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa Maximum Weight Capacity 180 lbs 81 7 kg 7175503 Tire Pressure Warning Sportsman 90 WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa Maximum Weight Capacity 225 lbs 102 kg 7175504 ...

Page 39: ...36 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 ...

Page 40: ...ety Safety Labels and Locations Sportsman 90 Rack Warning WARNING DO NOT TOW Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 lbs 7 kg Rear 30 lbs 14 kg 7174556 ...

Page 41: ...nder belt clutch guard To pre vent 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 part failure possible imbalance and excessive engine RPM which can result in serious injury or death 7174694 ...

Page 42: ...39 Youth Section ...

Page 43: ...cifications section beginning on page 162 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know Your safety and the safety of others is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re riding Pay attention when you see this sy...

Page 44: ... to shut the engine off quickly The button must be up before you can start the engine again 2 Horn Button Press the horn button to sound the horn 3 Throttle Control Press the throttle lever with your thumb when you want the ATV to go forward Always make sure the throttle control does not stick before you drive your ATV Read more about it on page 47 3 Throttle Control 1 Engine Stop Switch 2 Horn Bu...

Page 45: ...down on the kick start lever with your foot to start the engine Have an adult show you how it works Read more about how to use the kick start on page 68 5 Shift Lever The shift lever is on the right side of your ATV Read about how to use the shift lever on page 62 5 Shift Lever 4 Kick Start Lever ...

Page 46: ...s have an adult put gas in your ATV Never try to do it yourself 7 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the seat To replace the seat set it in place and push down on the seat above the latch Always make sure the seat is locked in place before riding 6 Gas Cap 7 Seat Latch ...

Page 47: ...ls the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured Always take your thumb off the throttle lever when you squeeze the brake levers 8 Rear Brakes 8 Front Brakes ...

Page 48: ...ched snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never ride without the tether strap attached to your right wrist and to your ATV Be careful not to let the cord get tangled around the handlebars or any part of your body 10 Tether Switch 9 Ignition Switch 10 Tether Switch 9 Ignition...

Page 49: ...46 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off ...

Page 50: ... t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close to the handlebar the ATV has a sticky throttle This means that something is wrong or broken and must be fixed before you can ride your ATV safely Never start the engine if you have a sticky throttle Y...

Page 51: ...de your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you ride n Have an adult check to see if your ATV needs more gas Children must never add their own gasoline This must always be done by an adult Before anyone adds gasoline to your ATV they must read the...

Page 52: ...check the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks n This last check is done with the engine running You must check to make sure that all three ways to stop the engine of your ATV are working the way they should Do you remember what they are If you can t remember the three ways to stop the engine go back to page 46 and review Then hav...

Page 53: ...driving an ATV Adults have riding rules too The rules help keep us safe when we ride X The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always drive safely Let s learn how to ride Always follow the safe riding rules found on the next pages You or others around you could be seriously hurt if you don t follow the safe riding rules ...

Page 54: ...es to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from scrapes and scratches Clothing Make sure your clothing fits properly If it s too small it could keep you from moving easily when you shift your weight If it s too big it could hang down and get caug...

Page 55: ...the ATV harder to drive You may lose control and hurt yourself and your passenger X Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests X Always be alert and pay attention to where you re driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do X Never follow another ATV to...

Page 56: ...ight Your ATV doesn t have lights that are safe for driving in the dark X Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them X Never ride on frozen water You could get hurt or you could even die All ice can be dan gerous X Ride your ATV only where you know it is safe to drive and where you have permission to drive Be careful of the things around you X Alw...

Page 57: ...54 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new Polaris ATV ...

Page 58: ...55 Adult Section ...

Page 59: ... with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame VIN ______________________________________________________________________________ Engine Serial Number _____________________________________________________________________ Key Number on the key __________________...

Page 60: ...e key clockwise to the ON position before starting the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running Always remove the ignition key when the vehicle is not in use Key Key OUTLAW SPORTSMAN ...

Page 61: ...ther emergency Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Use the choke to start a cold engine Push the choke lever to the left before starting the engine When the engine starts gradually return the choke lever to the OFF position as the engine warms up and runs smoothly Stop S...

Page 62: ...ghtly above the choke lever 1 Attach the tether strap securely to the vehicle and to the rider s right wrist 2 Shift the transmission to neutral The neutral light will come on when the lever is in neu tral See page 65 3 Turn the key to the ON position 4 Lock the parking brake 5 Push the engine stop switch up to the ON position 6 Press the start button ...

Page 63: ...ate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throt tle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation WARNING ...

Page 64: ...en position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the ETC system or r...

Page 65: ...ing Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Shift Pattern F Forward Gear N Neutral R Reverse NOTICE Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result Always shift when the vehicle is stationary and the engine is at idle F N R Shift L...

Page 66: ...t the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious injury or death Always apply both brakes at the same time Rear Brakes Front Brakes ...

Page 67: ...eeze and release the brake lever The parking brake will release automatically 5 Always lock the parking brake whenever the vehicle is left unattended WARNING Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operating the ATV Locked...

Page 68: ...this ATV after dark Use caution and drive at reduced speeds in conditions of reduced visibility This ATV is designed for off road use only Do not operate this ATV on streets or highways Indicator Lights Indicator lights on the ATV let you know when your ATV is in neutral or reverse WARNING Neutral Reverse Reverse Neutral OUTLAW SPORTSMAN ...

Page 69: ...el System Gas Cap The fuel tank filler cap is located directly below the handlebars Use unleaded gasoline with a minimum pump octane of 87 Refer to the specifications sec tion beginning on page 162 for fuel tank capacity Gas Cap ...

Page 70: ...nsporting ON For normal operation RES For reserve supply if main supply is exhausted The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON posi tion after refueling Sportsman 90 Fuel Valve OFF RES ON Outlaw 90 Fuel Valve ...

Page 71: ...n the left side of the ATV Tip A 10 12mm wrench is provided in the tool kit for removing or installing the lever If not installed make sure the rubber cap is on the kick start shaft to protect the rider Store the lever under the seat when it s not installed 5 Push the engine stop switch up to the ON position 6 Turn the key to ON 7 Place your foot on the kick start then thrust your heel downward to...

Page 72: ... gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Per form the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle ...

Page 73: ...dling gasoline See page 15 2 Check the oil level Add the recommended oil as needed Maintain the oil level in the proper range See page 109 3 Drive slowly at first Select an open area that allows room to familiarize yourself with operation and handling 4 Vary throttle positions Do not operate at sustained idle ...

Page 74: ...ist See page 72 6 Perform the following maintenance at the end of the break in period Item End of Break In Remarks See Page Engine oil change Perform break in oil change 110 Oil pre filter screen Clean filter with oil change 111 Transmission oil Perform break in oil change 114 Valve clearance See your dealer for inspection and adjustment ...

Page 75: ...e Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 129 133 Front suspension Inspect lubricate if necessary 106 Rear suspension Inspect lubricate if necessary 106 Steering Ensure free operation lubricate if necessary 134 136 Tires Check condition and pressure 143 Wheels fasteners Inspect ensure fastener tightness check that axle nuts are secured by cotter pins 145 ...

Page 76: ...d Check for proper operation 149 Brakelight Check for proper operation 147 Air filter pre filter Inspect clean or replace 140 Drive chain Check condition and slack refer to drive chain adjustment 137 Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any damaged compo nents or loose fasteners Riding gear Wear helmet goggles protective clothing 10 ...

Page 77: ... it run in an enclosed area 5 Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 6 Never exceed the maximum weight capacity of the vehicle When determin ing the weight you are adding to the vehicle include the weight of the opera tor accessories loads on the racks if equipped and the load on the trailer t...

Page 78: ...fore or while operating an ATV 9 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 Never operate a damaged ATV After any overturn or accident have a quali fied service dealer inspect the entire machine for possible damage 11 Never operate the ATV on a frozen body of water 12 Do not touch hot exhaust system com ponents Always keep combustible m...

Page 79: ...h the tether strap to the ATV and to your wrist 5 If the engine is cold use full choke by pushing the choke lever all the way to the left A warm engine will not require the use of the choke Tip The choke is fully on when the lever is pushed completely to the left The choke is off when the lever is pushed completely to the right The choke can be adjusted gradually depending on how much choke is nee...

Page 80: ... the starter for a maximum of five seconds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five seconds Repeat until the engine starts 10 If the engine slows or stops position the choke lever half way to allow proper engine warm up Vary the RPM slightly with the throttle to aid in warm up 11 When the engine idles smoot...

Page 81: ...moving 3 Shift the transmission to neutral 4 Stop the engine There are three ways to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV 5 Lock the parking brake 6 To avoid draining the battery always turn the key to the OFF position when the engine is not running ...

Page 82: ...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 the desired gear 7 Slowly release the brake lever 8 Slowly press the throttle with your right thumb and begin driving 9 Drive slowly at first Practice turning and using the throttle and brakes on level surfaces ...

Page 83: ...nside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly Practice making turns at slow speeds WARNING Turning improperly can result in vehicle overturn Never turn abr...

Page 84: ...recautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly ...

Page 85: ...urfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas ...

Page 86: ...f alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward Sideways skid Turn in direction of skid ...

Page 87: ...Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 15 maximum 3 Always check the terrain carefully before ascending any hill 4 Never climb hills with excessively slippery or loose surfaces 15 Maximum ...

Page 88: ...ttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 9 Remain alert and be prepared to take emergency action This may include quick dis mounting of the vehicle ...

Page 89: ... the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keeping your feet on the footrests 3 If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately ...

Page 90: ...teep hills 15 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when trav eling downhill can cause loss of control 5 Apply the front and rear brakes at the same time and very slightly to aid in slowing ...

Page 91: ...uphill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 5 Staying uphill of the ATV turn the handlebars full left 6 While holding the brake release the parking brake lock and slowly release the brake allowing the ATV to roll around to your right until it s pointing across the hill or sli...

Page 92: ... ATV from the uphill side keeping body weight uphill 8 Restart the engine 9 Squeeze the rear brake lever 10 Shift the transmission to forward gear 11 Release the parking brake and drive slowly controlling speed with the rear brake until the ATV is on more level ground 8 ft 2 4 m ...

Page 93: ...Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Stop the engine 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown in the illus tration 4 Turn the fuel valve off ...

Page 94: ...t ing in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never attempt to operate over large obsta cles such as rocks or fallen trees ...

Page 95: ...pth for your ATV is below the bottom of the footrests Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 If crossing a stream choose a crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing water Maximum Depth ...

Page 96: ...the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 98 Engine oil gearcase oil front and rear gearcases if equipped and all grease fittings need special attention If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for...

Page 97: ...g the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control which can result in serious injury or death Always follow these precautions when hauling cargo Place 1 3 of the cargo weight on the front rack and 2 3 on the rear rack Carrying loads on only one rack increases the chance of a tipover Slow down Allow more space for stopping the ATV when hauling cargo...

Page 98: ...or rope to secure the cargo Do not allow cargo or tie straps to hang over the edges of the racks Carry only small loads that fit on the racks Tall loads raise the center of gravity of the vehicle and may cause loss of control or a tipover Never allow a person to ride on the racks Never tow or pull an object behind the ATV A wagon sled or other object towed behind an ATV does not have brakes or ste...

Page 99: ...USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 1 c Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This ...

Page 100: ...rator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or engine case near the clutch box The installation of devices that effectively increase exhaust emissions beyond their legal lim its will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Electromagn...

Page 101: ...tment under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Record maintenance and service in the Maintenance Log beginning on page 182 ...

Page 102: ... parts available from your Polaris dealer Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation ...

Page 103: ... an authorized Polaris dealer perform these services Maintenance Chart Key X Perform these operations more often under severe use such as in dirty or wet condi tions to purge water or dirt contamination from grease fittings and other critical components E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions Q Dealer service ite...

Page 104: ...Pre Ride Check list 72 X Front suspension Daily X Rear suspension Daily Tires Daily X Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily X Engine oil level Daily XE Air filter pre filter main element Daily Inspect clean often replace as needed 140 X Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectri...

Page 105: ...st and lubricate if needed 137 CVT housing if equipped Weekly Drain water as needed check often if operating in wet conditions 121 Break in Maintenance After first 10 hours of operation Perform break in maintenance 69 XQ Brake lever travel brake freeplay 10 Monthly 100 160 Inspect regularly 129 133 QE Spark plug 10 Monthly 100 160 Clean check condition adjust gap replace as needed 116 Idle speed 1...

Page 106: ... filter screen 40 12 M 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours 111 X General lubrication 50 3 M 500 800 Lubricate all fittings pivots cables etc QE Valve clearance 50 3 M 500 800 Check clearance see your dealer for adjustments Carburetor float bowl 50 6 M 500 800 Drain bowl periodically and prior to storage QE Throttle cable ETC switch 50 6 M 5...

Page 107: ...or air intake ducts flange 50 6 M 500 800 Check for proper sealing air leaks Q Drive belt 50 6 M 500 800 See your Polaris dealer XQ Brake pad wear 50 6 M 500 800 See your Polaris dealer QE Fuel system 100 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years QE Fuel filter 100 12 M 1000 1600 Change filter 113 X Engine mounts 100 12 M 1000 ...

Page 108: ...pect for wear routing security apply dielectric grease to connec tors subjected to water mud etc Q Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 12 M 1000 1600 Inspect replace as needed Spark arrestor 300 36 M 3000 4800 Clean out 122 Q Toe adjustment Inspect periodically adjust when parts are replaced 134 ...

Page 109: ...ic Youth Oil or Synthetic SAE 40 See page 108 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 114 Drive Chain Polaris Chain Lube or SAE 80 90 See page 137 X Front Suspension A Arm Polaris All Season Premium Grease or grease conforming to NLGI No 2 Inspect tighten fasteners grease also after washing ATV or driving in water ...

Page 110: ...107 Maintenance Lubrication Guide Grease Points Grease Points ...

Page 111: ...o not use automotive oil See page 166 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 oil brands Under These Operating Conditions Use This Recommended Oil Outside air temperature is above 32 F 0 C Polaris Synthetic Youth Oil or Synthetic SAE40 Outside air temperature ...

Page 112: ...ean cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immedi ately 5 Add the recommended oil as needed 6 Reinstall the dipstick Dipstick Full Add Oil Safe Range ...

Page 113: ...osition the vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin ...

Page 114: ...mpletely 7 Wash the oil pre 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 clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug ...

Page 115: ...ommended oil Do not overfill See the specifications section beginning on page 162 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the engine and inspect for leaks 15 Check the oil level Add oil as needed to bring the level to the upper mark on the dip stick 16 Dispose of used oil properly ...

Page 116: ...r The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 98 Do not attempt to clean the fuel filter ...

Page 117: ... change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 166 for the part numbers of Polaris prod ucts 1 Position the vehicle on a level surface 2 Remove the fill plug 3 View the oil level through the fill hole 4 If the level is low add the recommended oil 5 Reinstall the fill plug Fill ...

Page 118: ...ve the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fill plug hole threads 7 Reinstall the fill plug Check for leaks 8 Dispose of used oil properly Gearcase Capacity Outlaw 90 11 8 oz 350 ml Sportsman 90 11 8 oz 350 ml ...

Page 119: ...lways use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspec...

Page 120: ...or throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Change 1 Remove the spark plug cap 2...

Page 121: ... result in serious engine damage Trans port the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined below This proce dure will allow short term operation only to drive the ATV to a trailer or towing vehicle 1 Move the ATV to dry land or at the very least to water below the footrests 2 Turn th...

Page 122: ...lace it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 12 If water has been ingested into the transmission follow the procedure on page 121 for drying the CVT Drain Screw ...

Page 123: ... and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in ...

Page 124: ...ion to neutral 3 Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and 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 Take the vehicle to your dealer for service as soon as possible NOTICE Exposure to salt water will...

Page 125: ...rt beginning on page 98 Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool suffi ciently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas WARNING ...

Page 126: ...n synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage Replace the arrestor if damage is found 4 Reinstall the arrestor 5 Torque the bolts to 7 ft lbs 9 5 Nm Arrestor Screen ...

Page 127: ...0 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTICE Continuous operation of the engine without proper jetting when required can cause p...

Page 128: ...arbure tor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclock wise will lower RPM ...

Page 129: ... either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable throttle limiting screw Speed limiting devices may be adjusted removed only by consumers when they determine that their child is capable of han dling the additional speed Per ANSI SVIA 1 2001 sec 6 2 the unrestricted top speed is less than 15 MPH for the ...

Page 130: ...rottle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten the jam nut after adjusting Jam Nut Screw ...

Page 131: ...tle for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay falls in to the acceptable limit Adjustment Nut 1 16 1 8 1 5 3 2 mm ...

Page 132: ... the intervals rec ommended in the Periodic Maintenance Chart beginning on page 98 If the free play isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specifications Model Front Brake Rear Brake 90cc Models 08 12 2 3 mm 08 12 2 3 mm Measure Freeplay ...

Page 133: ...he front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground 4 While rotating the left front wheel tighten the upper front brake adjuster nut on the right hand control 5 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn Front Brake Adjuster Nuts ...

Page 134: ...front brake adjuster nut on the right hand control 7 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 8 Verify that the right hand brake functions correctly 9 Verify that brake lever freeplay is at specification See page 129 10 Carefully lower the vehicle to the ground ...

Page 135: ...e rear tires should be slightly off the ground 4 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 5 When you begin to feel a slight drag in wheel rota tion loosen the wing nut one full turn 6 Verify that the left hand brake functions correctly 7 Verify that brake lever freeplay is at specification See page 129 8 Carefully lower the vehicle to the ground Rear Br...

Page 136: ... on the preceding pages use the following information to 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 sufficient stopping ability at the specified lever travel setting Component Total Lever Travel Front brake lever 1 3 4 45 mm Rear brake lever 2 ...

Page 137: ... Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long st...

Page 138: ...nt rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measure ment on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 If you discover improper alignment see your Polaris dealer for service ...

Page 139: ...have your dealer tighten them before operating the ATV Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The front and rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counter clockwise to make adjustments Adjuster ...

Page 140: ...rty or wet conditions See page 166 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 gasoline to clean the drive chain Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive componen...

Page 141: ...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 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 proc...

Page 142: ...r lock nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft lbs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid breaking the stud 5 Tighten the four rear housing mount bolts to 43 ft lbs 60 Nm Housing Mount Bolts Chain Adjuster ...

Page 143: ...ring clips and remove the cover 3 Remove the foam air filter Wash the foam filter in 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 Support Screen Cover Clips Foam Filter ...

Page 144: ...l or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat NOTICE Never operate the ATV with the filter element removed Dirt will enter the engine causing rapid wear and severe damage to the engine ...

Page 145: ...he adjustment procedures exactly or see your Polaris dealer for service The handlebars can be adjusted for rider preference 1 Remove the pod to access the handlebar bolts Loosen 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 each bolt equally to prev...

Page 146: ... or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires WARNING ...

Page 147: ...s worn to 1 8 3 mm or less Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts 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 wheel 1 8 3 mm Wheel Bolts ...

Page 148: ...in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Install the wheel bolts and finger tighten them 4 Lower the vehicle to the ground 5 Securely tighten the bolts to 22 ft lbs 30 Nm ...

Page 149: ...th a cotter pin installed must be service by an authorized Polaris dealer Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer ...

Page 150: ...t doesn t work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the lamp and replace it with a new recommended lamp 3 Test the light for proper operation 4 Reinstall the lens cover Screws Cover Lamp ...

Page 151: ...ver or pod to access the lamps 2 Remove the indicator wire connections from the harness 3 Remove the nut from the back side of the indicator lamp 4 Remove the lamp 5 Apply dielectric grease to the socket and install the new lamp 6 Reverse the steps to reinstall all components ...

Page 152: ...the light assembly 4 Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out 5 Install the new lamp Make sure the filament is horizontal 6 Reinstall the lamp retainer Press the retainer inward and turn it clockwise about 1 4 turn 7 Start the engine to make sure the lights come on If the lights do not ...

Page 153: ...black cable last The battery in your Polaris ATV is a sealed battery The sealing strip cannot be removed Never add water to this type of battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop t...

Page 154: ...ry Removal 1 Disconnect the hold down straps securing the electrical box and battery in position 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Lift the battery out of the ATV ...

Page 155: ...d can damage the battery and result in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 1 Set the battery in its holder 2 Connect and tighten the red positive cable first 3 Connect and tighten the black negative cable last 4 Attach the hold down strap 5 Verify that cables are properly routed ...

Page 156: ...ng storage and recharge as needed to maintain a full charge Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surf...

Page 157: ... lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles...

Page 158: ...als Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system ...

Page 159: ...ish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish ...

Page 160: ...the vehicle as recommended See page 153 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge ...

Page 161: ...ge period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stop the eng...

Page 162: ...ter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 98 Transmission Oil Engine Oil Brake Fluid ...

Page 163: ...ke sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated 4 Cover the vehicle with an appropriate cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation ...

Page 164: ... Secure the fuel cap oil cap and seat 5 Turn the fuel valve off 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting the unit Accessories Polaris has a wide range of accessories available for your ATV Please see your Polaris dealer ...

Page 165: ...pe 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gallons 6 4 liters Fuel Reserve Capacity 23 gallons 86 liters Starting Electric with kick start backup Drive System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel ...

Page 166: ...t Tires 19 x 7 8 3 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa Dry Weight 270 lbs 122 4 kg Length Width Height 61 25 156 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Brake Light Standard Daytime Running Lights Standard ...

Page 167: ... type 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 2 gallons 7 7 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel ...

Page 168: ... Parking Brake Mechanical Lock Front Tires 19 x 7 8 3 psi 20 7 kPa Rear Tires 18 x 9 5 8 3 psi 20 7 kPa Dry Weight 289 lbs 131 kg Length Width Height 61 75 157 cm 36 75 93 cm 38 5 98 cm Wheel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Brake Light Standard Daytime Running Lights Standard ...

Page 169: ...uth Oil qt 95 l 2876249 Synthetic Youth Oil gal 3 8 l 2872175 Semi Synthetic 20W 40 Oil qt 95 l 2872176 Semi Synthetic 20W 40 Oil gal 3 8 l 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2872348 Chain Lube Aerosol ...

Page 170: ...167 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease 3 oz 89 ml 2871423 All Season Premium Grease 14 oz 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus ...

Page 171: ... system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter R...

Page 172: ...p charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs ...

Page 173: ...lugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer ...

Page 174: ...ge 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 voltage Recharge battery with 5 amp charger Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris...

Page 175: ...uel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer ...

Page 176: ...k plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery with 5 amp charger Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electroni...

Page 177: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed ...

Page 178: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE ...

Page 179: ...S OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law ...

Page 180: ...rform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will ...

Page 181: ...r s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells th...

Page 182: ...w country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or...

Page 183: ...irements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in thi...

Page 184: ...ON TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS 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 if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not c...

Page 185: ...l to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 10 Hours Break in 40 Hours 50 Hours 80 Hours ...

Page 186: ...183 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours ...

Page 187: ...184 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 188: ...185 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 189: ...stant Variable Transmission 120 Consumer Product Safety 9 CVT Drying 121 CVT System 120 Cylinder Head Torque 118 D Daytime Running Lights 149 Drive Chain 137 Drive Chain Slack 138 Drive Chain Slack Adjustment 139 Driving Downhill 87 Driving in Reverse 81 Driving on a Sidehill 86 Driving on Slippery Surfaces 82 83 D Driving Over Obstacles 91 Driving Procedure 79 Driving Through Water 92 93 Driving ...

Page 190: ...ide 106 107 M Main Key Switch 57 Maintenance Chart 98 105 Making Turns 80 Modifications 12 O Oil 108 Oil Change Engine 110 112 Oil Change Transmission 115 Oil Check Engine 109 Oil Check Transmission 114 Oil Engine 108 Operator Restrictions 13 P Parking on a Hill or Incline 90 Periodic Maintenance Chart 98 105 Polaris Products 166 Polishing 156 Pre Ride Inspection 72 73 R Restrictions Age 13 Riding...

Page 191: ...ep Hills 21 Operating Over Obstacles 27 Operating in Deep Water 28 Operating Without Instruction 14 Physical Control of the ATV 19 Physical Skills 30 Protective Apparel 16 Skidding or Sliding 27 Slippery Terrain 25 Stalling While Climbing a Hill 24 Turning Improperly 20 Unauthorized Use of the ATV 31 Unfamiliar Terrain 26 Using Alcohol or Drugs 17 S Safety Words and Symbols 6 Seat Latch 43 Severe ...

Page 192: ...8 Throttle Control 41 Throttle Lever 61 Throttle Stop Speed Control 127 Tire Tread Depth 144 Tires 143 Toe Alignment 134 135 Transmission Oil 114 115 Transporting the ATV 161 Turning Around on a Hill 88 89 V Vehicle Identification Numbers 56 Vehicle Immersion 118 119 W Warranty 174 181 Warranty Emissions 180 181 Washing the ATV 154 Wheel Hub Tightening 146 Wheel Installation 145 Wheel Nuts 146 Whe...

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Polaris Sportsman 9921796, Owner'S Manual

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