Polaris 2001 Youth ATV Models Owner's Manual PDF

Read this manual carefully. It contains important safety information. Scrambler 50 - No one under the age of 6 should ride this vehicle.

Sportsman 90 and Scrambler 90 - No one under the age of 12 should ride these vehicles.

2001 YOUTH ATV MODELS Owners Safety and Maintenance Manual

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or

other reproductive harm.

WARNING

Indicates a potential hazard which could result in severe injury or death.

Part No. 9916424

Improper ATV use can result in SEVERE INJURY or DEATH

Always use an approved helmet and protective gear

Never use on public roads Never carry passengers Never use with drugs or alcohol

NEVER operate: without proper training or instruction; at speeds too fast for your skills or the conditions; on public roads - a collision can occur with another vehicle; with a passenger - passen- gers affect balance and steering and increaqse risk of losing control.

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns; avoid paved surfaces - pavement may seriously affect handingl and control.

i

FOREWORD

Congratulations and thank you from Polaris Industries Inc. for purchasing one of our all-terrain vehicles (ATVs). Built with American engineering andmanufacturing know- how, it is designed to provide superior riding comfort, enjoyment, and safety.

This manual is furnished to ensure that the operator and parents are aware of safe operating procedures. It also includes information about the general care and main- tenance of your ATV.

Carefully read the following pages. If you have any questions regarding this ATV con- tact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge and facilities to provide you with the best service possible.

ii

PROTECT YOUR SPORT

Know all local, state/province riding laws;

Respect your vehicle;

Respect the environment; and

You will gain the respect of others.

We also advise you to strictly follow the recommended maintenance program as out- lined. This preventive maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals.

All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to make product changes and improvements which may affect illustrations or explanations.

No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc.

Illustrations included in this manual are general representations of parts having a similar function. Your model may differ.

iii

INTRODUCTORY SAFETY MESSAGE TO PARENTS ANATV ISNOTATOYANDCANBEHAZARDOUSTOOPERATE. AnATVhandles differently from other vehicles including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles, if you fail to take proper precautions. Children differ in skills, physical abilities, and judgement. Some children may not be able to operate an ATV safely. Parents should supervise their childs use of the ATV at all times. Parents should permit continued use only if they determine that the child has the ability and maturity to operate the ATV safely.

Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH.

Read this manual and all labels carefully and follow the operating procedures de- scribed.

Never operate an ATV without proper instruction. Take a training course. Riders should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses nearest you.

iv

Always follow the age guidelines for your machine. Youth ATVs are designed and intended for use by children in two age groups. The Scrambler 50 is for children not less than 6 years of age. The Scrambler 90 and the Sportsman 90 are for chil- dren not less than 12 years of age. No children under the age of 16 should ride an ATV designed and sold for an adult.

Do not allow other children to ride this ATV unless they have read the manual, seen the instructional video and taken and passed a Polaris approved riding skill test.

Always avoid operating an ATV on any paved surfaces, including sidewalks, drive- ways, parking lots and streets.

Never operate an ATV on any public street, road or highway, even a dirt or gravel one.

Never operate an ATV without wearing an approved helmet that fits properly. You should also wear eye protection (goggles or face shield), gloves, boots, long- sleeved shirt or jacket, and long pants.

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

Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience.

v

Never attempt wheelies, jumps or other stunts.

Always inspect your ATV each time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and sched- ules described in this manual.

Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

Always go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

Never operate on excessively rough, slippery or loose terrain.

Always follow proper procedures for turning as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at ex- cessive speed.

Always have the ATVchecked byan authorizedPolaris dealer if it has been involved in an accident.

Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.

vi

Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill. Never climb hills with exces- sively slippery or loose surfaces. Shift yourweight forward. Never open the throttle suddenly or make sudden gear changes. Never go over the top of any hill at high speed.

Always follow proper procedures for going down hills and for braking on hills as de- scribed in this manual. Check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until you havemastered the turning technique described in this manual on level ground. Avoid crossing the side of a steep hill if possible.

vii

Always use proper procedures if you stall or roll backwards when climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Dis- mount on the uphill side or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual.

Always check for obstacles before operating in a new area. Never attempt to oper- ate over large obstacles, such as large rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of con- trol.

Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg. 98), go slowly, bal- ance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sud- den throttle changes.

Wet brakesmay have reduced stopping ability. Test your brakesafter leavingwater. If necessary apply them lightly several times to let friction dry out the pads.

viii

Always use the size and type tires specified in this manual. Alwaysmaintain proper tire pressure as described in this manual.

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

Never exceed the stated load capacity for an ATV. Cargo should be properly distrib- uted and securely attached. Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking.

FORMORE INFORMATIONABOUTATV SAFETY, call the Consumer Product Safe- ty Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.

Additional Important Information...

Due to our concern for the safety of our customers and the general public, Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle; ormake any othermodifications to the vehicle for these purposes. Anymodi- fications to the original equipment of the ATV substantially increase the risk of bodily injury. Please be aware that these modificationsmay create a substantial safety haz- ard.

ix

Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.

We also advise you to strictly follow the recommendedmaintenance programoutlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various mileage intervals.

NOTE: The addition of certain accessories may change the handling characteristics of the ATV. Be certain any accessories added to this ATV have been approved by Polaris. Familiarize yourself with their function and affect on the ATV.

Indicates a potential hazard which could result in severe injury or death.

x

TABLE OF CONTENTS

RIDERS SECTION R-1 - R-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNDERSTANDING WARNINGS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SAFETY AND DESCRIPTION OF LABELS 5-18. . . . . . . . . . . . . . . . . . . . .

DAILY PRE-RIDE CHECK 20-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION WARNINGS 22-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBERS 47-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL AND PARTS FUNCTIONS 49-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTING THE ENGINE 70-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDING GEAR 72-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE BREAK IN PERIOD 74-76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CARRYING LOADS 77-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DAILY PRE-RIDE CHECK 81-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RIDING 84-103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

xi

TABLE OF CONTENTS PVT SYSTEM OPERATION 104-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY 106-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

NOISE EMISSION CONTROL SYSTEM REGULATION 112-114. . . . . . . . . . . . . . .

MAINTENANCE 115-161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 162-168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WIRING DIAGRAMS 169-170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLE SHOOTING 171-172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY 173-178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX 179-180. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R--1

RIDERS SECTION

R--2

KNOW YOUR MACHINE

PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride an ATV. You must set boundaries and adhere to them, keeping your childs safety foremost in your mind. Never allow your child to operate this machine without adult supervision.

CHILDREN: Before you ride your new Polaris ATV, there are some important things you should know. How to keep safe is the most important thing. You must also learn some things that will keep you and those around you safe while you are riding.

R--3

KNOW YOUR MACHINE Pay attention when you see this symbol.:

This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you dont, you could get hurt verybadly or even killed. Your safety is involved!

R--4

KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time, lets learn about the controls on your new machine.

1. Engine Stop Switch - When the engine is running, you can slide this button to the left or the right and the engine will stop. The stop switch must be in the middle position to start the engine again.

2. ThrottleControl (A) -Thismakes your ATV go forward when you press it with your thumb. You must always make sure the throttle control does not stick before you operate your ATV. Read more about it on page R--12.

1

RUN OFFOFF

2A

R--5

KNOW YOUR MACHINE 3. Kick Starter (B) - If your battery is too

weak to start your machine, you can push on this with your foot to start the engine. Have an adult show you how this works. There is more information on how to use the kickstart on page 69.

3

B

R--6

KNOW YOUR MACHINE 4. Gas Cap - This is where the gas goes

that will run your ATV. Your ATV will not run without gas. Only adults should fill the gas tank.

1

4

Always have an adult put gas in your machine.

R--7

KNOW YOUR MACHINE 5. Brake Lever (C) - Squeeze this

towards the handle bar to make your ATV slow down or stop. The right hand lever (C-1) controls the front brake. The left hand lever (C-2) controls the rear brake. To slow down or stop, squeeze both brake handles at the same time.

5

C-1

C-2

Always apply both brakes at the same time or loss of vehicle con- trol can occur resulting in serious injury or death. Always take your thumb off the throttle control when you pull the brake lever.

R--8

KNOW YOUR MACHINE 6. Ignition Switch - This key must be turned on before pushing the starter button. You can also use this key to turn off the engine. You can find it on the Right-hand side of the Scramblers (D) and on the pod of the Sportsman (E).

D

E

6

R--9

KNOW YOUR MACHINE 7. Tether Strap/ Switch - This must always be attached snugly to your right wrist and your machine when you are riding. If you fall off your ATV, the tether will pull off the switch and the engine will stop. Put one end of the tether strap around your right wrist. The other end must be attached to the ATV. Always attach the tether strap before you ride. (Sportsman - F and Scramblers - G)

F

G

7

Never ridewithout the tether strap attached to your rightwrist andmachine. Be careful not to get the cord tangled around the handlebars or any part of your body.

R--10

KNOW YOUR MACHINE

Lets review the three ways to stop your ATV.

1. Sliding the shut off switch to the left or right.

2. Disconnecting the tether strap will shut off the engine.

3. Turning the key to off will shut off the engine.

R--11

KNOW YOUR MACHINE

1

2

3

R--12

PRE RIDE CHECK You are almost ready to have an adult start your ATV. Before the ATV is started for the first time, youmust do aPRE-RIDECHECK. In fact, every time you ride your ATV you must have an adult help you check these things before starting it. Lets learn about these things now.

Make sure the throttle doesnt stick. Check this by pushing the lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it. If it comes back slowly or stays open, you have a sticky throttle. This means that something is wrong or broken.

If you have a sticky throttle, do not start the engine. You could get hurt if you ridewhen youhavea sticky throttle. Have anadult or your PolarisDeal- er fix the throttle.

R--13

PRE RIDE CHECK Make sure the brakes dont stick. Check the brake levers by squeezing

them toward the handlebar and then letting it go. They should come right back towhere theywere before you squeezed. If they goback slowly or stay on, your brakes are sticking.

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

If you have sticky brakes, do not start the engine. You could get hurt if you ride when you have sticky brakes. Have an adult or your Polaris Dealer fix the sticky brakes.

R--14

PRE RIDE CHECK Have an adult check the gas level to see if your ATV needsmore. Children

should never add their own gasoline. This should always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owners Manual.

Haveanadult check the engine oil levelwhen the engine is cold. Theengine is very hot after it has been running. It could burn you. Children should never check the oil on their own. An adult should be in charge of keeping the gas and oil levels to the full marks.

Always have an adult put gas in your machine.

R--15

PRE RIDE CHECK This last check is done with the engine running. You must check to make

certain that ALL THREEWAYS TO STOP your ATV are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--10 and review.

R--16

RIDING RULES Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you wont be safe when you ride. Remember that safety while you ride is the most important thing. Lets learn how to ride!

" Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder to drive. You may lose control and hurt yourself and your passenger.

"Make sure you knowwhere you are going to drive when your ATV is started. Make sure the area is safe all around your ATV.

You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.

R--17

RIDING RULES "Alwayswear the right kind of clothingwhen

you are riding your ATV. You will need a good helmet with a face shield or goggles. Wear a long sleeved shirt or jacket, gloves, long pants, and boots. Make sure your clothing fits properly. If it is too small, it could keep you from moving easily. If it is too big, it could hang down and get caught in a moving part.

L

L

L

L

L

L

R--18

RIDING RULES

"Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult.

" Never ride on public trails.

" Always drive your ATV while sitting down. Keep both hands on the handlebars and keep both feet on the running boards.

You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed.

R--19

RIDING RULES "Dont ride your ATV on roads or over railroad tracks. Your ATVmakes noise

that will keep you from hearing cars, trucks or trains that may be coming towards you.

" Dont ride at night.

" Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away from them. Never ride on frozen water. You could get hurt or you could even die. All ice can be dangerous!

" Always be alert and pay attention to where you are driving. Pay attention to other drivers and be even more careful around them because you dont know what theyre going to do.

R--20

RIDING RULES " Never follow another ATV too closely. Always allow lots of time and space

to stop your ATV.

" Only ride your ATV where you know it is safe to drive. No driving over the flower garden or on the little trees you planted. Be careful of the things around you.

" Always attach the tether strap to your right wrist and machine before riding.

Respect your ATV; respect your environment;

and you will earn the respect of everyone.

1

UNDERSTANDING WARNINGS

ATTENTION:

Always follow the age guidelines on the machine. YOU MUSTMAKE CERTAIN THE OPERATOR(S) UNDERSTAND ALL WARNINGS AND THE OWNERS MANUAL BEFORE OPERATION.

KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!.

It is the parents responsibility to teach their children the proper and safe way to ride any ATV. This should be done by reading the owners manual with your children be- fore they first use the ATV and periodically afterwards.

SAFETY TRAINING.

When you purchased this vehicle your dealer presented a hands-on safety training course covering all aspects of ATV safety. In addition, you were provided with certain printed material and a video which instructs operators on safe operating procedures.

2

UNDERSTANDING WARNINGS

You should review this information with your child on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, safety training can obtained at no charge from any authorized Polaris dealer.

Failure to follow the warnings contained in this manual can result in severe INJURY OR DEATH.

NOTE: Illustrations used in this manual are for general representation only. Your model may differ. SAFETY ALERT

WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all WARNINGS in this manual carefully. Always follow their instructions.

3

UNDERSTANDING WARNINGS

The following precautionary signal words are used throughout this manual to convey the following messages:

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved!

Indicates a potential hazard which could result in severe injury or death.

4

UNDERSTANDING WARNINGS

The following precautionary signal words are used throughout this manual to convey the following messages:

Indicates a potential hazard which may result inminor personal injury ordamage to the ATV.

NOTE The word NOTE: in this manual will alert you to key information or instructions.

Indicates asituation that can result in damage to themachine.

5

GENERAL SAFETY AND DESCRIPTION OF LABELS NOTE: Warning decals have been placed on the vehicle for the protection of the operator(s). Read and follow the instructions on each decal carefully. In the event any decal be- comes illegible or comes off, contact your Polaris dealer for a replacement. Any safe- ty decal needing replacement will be provided by Polaris at no charge. The part num- ber is printed on the decal.

6

GENERAL SAFETY AND DESCRIPTION OF LABELS

1

WARNING

7

GENERAL SAFETY AND DESCRIPTION OF LABELS Improper ATV use can result in SEVERE INJURY OR DEATH. Always use an approved helmet and protective gear; Never use on public roads Never carry passengers; Never use with drugs or alcohol NEVER operate: without proper training or instruction; at speeds too fast for your skills or the conditions; on public roads - a collision can occur with another vehicle; with a passenger - passengers affect balance and steering and increase risk of losing control. ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns; avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNERS MANUAL IS MISSING, CONTACT A POLARIS DEAL- ER FOR A REPLACEMENT.

8

GENERAL SAFETY AND DESCRIPTION OF LABELS

2 Kids under age 6 should NEVER operate this ATV. Kids under 6 have an increased chance of losing control, which could result in severe injury or death.

Adult supervision is required.

Make sure operators follow Owners Manual and labels.

Make sure operators watch the safety video and pass the ATV Training Course.

Never operate this ATV on HILLS steeper than 15 degrees 15. To prevent flipover on hilly terrain, use throttle

and brakes gradually.

S

S

S

S

S

2

(Found on Scrambler 50)

9

SAFETY WARNING AND OPERATION DECALS S Kids under age 6 should NEVER operate this ATV. Kids under 6 have an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owners Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course.

S Never operate this ATV on HILLS steeper than 15 degrees 15. To prevent flipover on hilly terrain, use throttle

and brakes gradually.

10

SAFETY WARNING AND OPERATION DECALS

2

Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing control, which could result in severe injury or death.

Adult supervision is required.

Make sure operators follow Owners Manual and labels.

Make sure operators watch the safety video and pass the ATV Training Course.

Never operate this ATV on HILLS steeper than 15 degrees 15. To prevent flipover on hilly terrain, use throttle

and brakes gradually.

S

S

S

S

7079091

2

(Found on Scrambler 90 and Sportsman 90

S

11

GENERAL SAFETY AND DESCRIPTION OF LABELS S Kids under age 12 should NEVER operate this ATV. Kids under 12 have an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owners Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course.

S Never operate this ATV on HILLS steeper than 15 degrees 15. To prevent flipover on hilly terrain, use throttle

and brakes gradually.

12

GENERAL SAFETY AND DESCRIPTION OF LABELS

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 2 REAR 2

maximum weight capacity (Gross Vehicle Weight) INCLUDING MACHINE,

DRIVER AND CARGO IS _____ LBS.

(Found on Scrambler 50 and Scrambler 90)

3

3 4

WARNING

13

GENERAL SAFETY AND DESCRIPTION OF LABELS 4

WARNING

Indicates a potential hazard which could result in severe injury or death.

14

GENERAL SAFETY AND DESCRIPTION OF LABELS

5

6

15

GENERAL SAFETY AND DESCRIPTION OF LABELS D Operation of this vehicle without the filter element will severely damage the engine.

D Clean air filter often, more frequent cleaning required in dusty conditions.

(on rear of seat) 6

D Specific carburetor jetting and adjustments are

required depending on temperature and altitude. See your Owners Manual.

Factory Setting: D 40 to 80 F. at 0-3000 feet. (5 to 27 C. at 0-900 meters)

ATTENTION

5

16

GENERAL SAFETY AND DESCRIPTION OF LABELS

7

10

8 9

17

GENERAL SAFETY AND DESCRIPTION OF LABELS

7 Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death.

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Maximum Front Rack Load 10 lbs.

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Maximum Rear Rack Load 20 lbs.

8 9

(Found on the Sportsman 90)

WARNING

18

GENERAL SAFETY AND DESCRIPTION OF LABELS

MANUFACTURED BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS.

CE VHICULE EST UN VHICULE TOUT TERRAIN QUI NiEST PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS.

IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE (PSI): FRONT 2 REAR 2

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight INCLUDING MACHINE, DRIVER AND CARGO IS 423 LBS.)

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unse- cured loads will increase your risk of losing control. Loads should be centered, carried as low as possible, and firmly se- cured to the racks. With dual racks, load distribution 1/3 front 2/3 rear is best. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the rack.

Read Owners Manual for more detailed loading information.

S

S

(Found on Sportsman 90)

10

19

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Industries Inc. They should then regularly practice the skills learned in the course and the operating techniques described in the Owners Manual. For more information about the training course, contact an authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

20

DAILY PRE-RIDE INSPECTION

Use the following checklist to verify yourmachine is in proper working order each time you ride.

Item/Inspection Procedure 1. Tires - check condition and pressures

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

3. All brakes - check operation, adjustment.

4. Throttle - check for free operation and closing

5. Brakelight - check for proper operation.

This ATV must be inspected each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result.

21

DAILY PRE-RIDE INSPECTION 6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins

8. Drive chain - condition and slack; refer to drive chain adjustment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual looseness in any area

11. Loose parts - visually inspect vehicle for any damaged components or loose nuts/ bolts or fasteners

12. Operators helmet, goggles and clothing

Indicates a potential hazard which could result in severe injury or death.

22

OPERATION WARNINGS

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are recommended, he or shemay not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident. HOW TO AVOID THE HAZARD Follow the age guidelines printed on your machine.

WARNING

23

OPERATION WARNINGS

POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to allow the operator to shift position as needed during op- eration. It is not for carrying passengers.

WARNING

24

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV on paved surfaces, including side- walks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of theATV, andmay cause the vehicle to goout of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever pos- sible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.

WARNING

25

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.

WARNING

26

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and pro- tective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye protection can result in an acci- dent and increases your chances of a severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always wear an approved helmet which fits properly. You should also wear: eye protection (goggles or face shield); gloves; boots; long-sleeved shirt or jacket; and long pants.

WARNING

27

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.

WARNING

28

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an acci- dent. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience.

WARNING

Indicates a potential hazard which could result in severe injury or death.

29

OPERATION WARNINGS

POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Dont try to show off.

WARNING

30

OPERATION WARNINGS

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owners Manual.

WARNING

31

OPERATION WARNINGS

POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the footrest, your foot or leg may come into contact with the rear wheels, which could injure you or cause an accident. HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during operation.

WARNING

32

OPERATION WARNINGS

POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control.

HOW TO AVOID THE HAZARD Go slowly and be extra careful when operating on unfamiliar terrain. Always be alert to changing terrain conditions when operating the ATV.

WARNING

33

OPERATION WARNINGS

POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn.

HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain. Always be especially cautious on these kinds of terrain.

WARNING

34

OPERATION WARNINGS

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owners Manual. See page 86 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed.

WARNING

35

OPERATION WARNINGS

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills

as described in the Owners Manual. See pages 91 through 96. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift yourweight for- ward. Never open the throttle suddenly. The ATV could flip over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another ve- hicle or person could be on the other side of the hill.

WARNING

36

OPERATION WARNINGS

POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills

as described in the Owners Manual. See page 94. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift yourweight backward. Never go down a hill at high speed. Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side. Go straight down the hill where possible.

WARNING

37

OPERATION WARNINGS

POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until

you have mastered the turning technique as described in the Owners Manual on level ground. See page 96. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing the side of a hill: Always follow proper procedures as described in the Owners Manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

WARNING

38

OPERATION WARNINGS

POTENTIAL HAZARD Stalling, rolling backwards or improperly dismount- ing while climbing a hill. WHAT CANHAPPEN Could result in ATV overturn- ing. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keepweight uphill. Ap-

ply the brakes. Lock parking brake after you are stopped. If you begin rolling backwards: Keep weight uphill; never apply engine power. Never apply the rear brake while rolling backwards. Apply the front brake slowly by squeezing the RH lever. When fully stopped, apply rear brake as well, and then lock parking brake. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure de- scribed in the Owners Manual. See page 96.

WARNING

39

OPERATION WARNINGS

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to over- turn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance of skidding or sliding out of control.

WARNING

Indicates a potential hazard which could result in severe injury or death.

40

OPERATION WARNINGS

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owners Manual.

WARNING

41

OPERATION WARNINGS

POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water.

WARNING

42

OPERATION WARNINGS

POTENTIALHAZARD Operating thisATV throughdeep or fast flowingwater. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deepor fast flowingwater. If you canot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully avoiding sudden movements, maintain a slow and steady forward motion, do not make sudden turns or stops, and do not make sudden throttle changes. See page 98. Remember that wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them several times to let fric- tion dry out the pads.

WARNING

43

OPERATION WARNINGS

POTENTIAL HAZARD Operating thisATVwith improper tires, orwith improper oruneven tire pressure. WHAT CAN HAPPEN Use of improper tires on this ATV, or operation of this ATV with improper or un- even tire pressure, may cause loss of control, and increases the risk of an acci- dent. HOW TO AVOID THE HAZARD Always use the size and type tires specified in theOwners Manual Supplement for this vehicle. Alwaysmaintain proper tire pressure as described in the Owners Manual Sup- plement.

WARNING

44

OPERATION WARNINGS

POTENTIAL HAZARD Overloading this ATV WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached.

WARNING

45

OPERATION WARNINGS

After a rollover or an accident, have a qualified service dealer check the com- plete machine including, but not limited to, brakes, throttle and steering for possible damage.

Safe operation of this rider active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death.

WARNING

WARNING

Indicates a potential hazard which could result in severe injury or death.

46

OPERATION WARNINGS

POTENTIAL HAZARD Operating this ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may cause changes in handling which in some situations could lead to an accident. HOW TO AVOID THE HAZARD Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this vehicle should be genuine Polaris In- dustries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer.

WARNING

47

VEHICLE IDENTIFICATION NUMBERS

21

48

VEHICLE IDENTIFICATION NUMBERS Record these numbers from your ATV in the spaces provided.

2. Frame VIN (found on the front of frame below steering post)

1. Engine Serial Number (Left side of engine crankcase)

Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut bymating it with your existing key.

The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining insurance or whenever replacement parts are required. In the event your vehicle were stolen these numbers are essential to the recovery and identification of your ATV.

49

CONTROL AND PARTS FUNCTIONS Engine Electrical Switches

1 - Main Switch - Located on the Right-hand side of the Scram- blers (A) and on the pod of the Sportsman (B). This switch is operated with a key and must be turned clock- wise to the on position to start the engine.

A

B

1

50

CONTROL AND PARTS FUNCTIONS

2 - Emergency Engine Stop Switch The engine will not start or run when the switch is in its off position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the emergency engine stop switch shut off all electrical power to the entire vehicle. To stop the engine, slide the stop switch right or left to the off position.

RUN OFFOFF

2

51

CONTROL AND PARTS FUNCTIONS

3 - Engine Start Button - To start the engine, make certain the tether switch is securely plugged into the machine and attached to the riders right wrist. Turn the key to the on position, set the parking brake, and push the start button.

NOTE: Remember to release the park brake before driving forward.

3

52

CONTROL AND PARTS FUNCTIONS

Engine or driveline damage could occur if the machine is driven without the park brake released.

This ATV is not equipped with lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at reduced speeds in conditions of reduced visibility. Do not operate this machine after dark.

53

CONTROL AND PARTS FUNCTIONS Engine Throttle

Indicates a potential hazard which could result in severe injury or death.

Do not start or operate an ATV with sticking or improperly operating throttle controls. A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can re- sult in the throttle lever sticking during riding and cause an accident. Always check the lever for free movement and return before starting the en- gine and occasionally during riding.

54

CONTROL AND PARTS FUNCTIONS

Throttle Lever Engine speed and vehicle movement are con- trolled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is re- leased. This vehicle is equipped with an Electronic Throttle Control (ETC) which is designed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the opera- tor releases the throttle lever.

1

55

CONTROL AND PARTS FUNCTIONS

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not at- tempt to modify the ETC system or replace it with any after market throttle mechanism.

56

CONTROL AND PARTS FUNCTIONS

Switches

Each Polaris ATV has a main switch. It is located on the right hand side of the machine or headlight pod and operated with a key.

Indicator Lights

Each Polaris ATV has indicator lights. This model has a low oil warning light. When this red dot is lit, it is indicating a low oil level.

57

CONTROL AND PARTS FUNCTIONS Front and Rear Brakes

To activate the rear brake (A), squeeze the left hand lever to- ward the handlebar.

The front brakes (B) are activated by squeezing the lever on the RH handlebar.

A

B

Always apply both brakes at the same time or loss of vehicle con- trol can occur resulting in seri- ous injury or death.

58

CONTROL AND PARTS FUNCTIONS Parking Brake

Setting the Parking Brake 1. Squeeze the left hand brake lever (A).

2. Push the park brake lock (B) down. This will pre- vent the lever from returning to the released position.

Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the park- ing brake is left on while the ATV is operated.

A

B

59

CONTROL AND PARTS FUNCTIONS 3. To release the parking brake lock, squeeze the brake lever. The parking brake will

release automatically.

Important Safeguards

NOTE: This vehicle has a PVT system which is always in forward. Always lock the park brake before starting the engine.

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

Before starting the engine, make certain the park brake is fully locked. Since the machine has a transmission that is always in forward, throttle activation to warm the engine will make the machine go forward if the park brake is not locked.

Once the engine has warmed enough for operation, release the park brake and gently apply the throttle to go forward.

60

CONTROL AND PARTS FUNCTIONS

Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline.

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

D Do not smoke or allow open flames or sparks in or near the area where re- fueling is performed or where gasoline is stored.

D Do not over fill the tank. Do not fill the tank neck.

D If you get gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

D Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time.

D Shut off fuel valve whenever the ATV is stored or parked.

61

CONTROL AND PARTS FUNCTIONS

Indicates a potential hazard which could result in severe injury or death.

WARNING

The engine exhaust from this prod- uct contains chemicals known to

cause cancer, birth defects or other reproductive harm.

62

CONTROL AND PARTS FUNCTIONS PVT System

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the fol- lowing responsibilities to make sure this system remains safe: D Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of bal- ance, creating vibration and additional loads on components.

D Routine maintenance is the responsibility of the owner. Always follow rec- ommended maintenance procedures. See your dealer!

D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation.

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

63

CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System

Fuel System

The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a ca- pacity of 1.3 gallons (5 liters). Use un- leaded gasoline with a minimum pump oc- tane number of 87 octane.

1

64

CONTROL AND PARTS FUNCTIONS

The fuel valve is located on the engine, be- hind the right front fender and has three positions:

OFF: For vehicle storage and whenever transporting.

ON: For normal operation.

RES: For reserve supply in the event of main supply exhaustion.

NOTE: There is about a 7 to 10 mile (11.2 to 16 km) range on reserve gas. Always refill the gas tank as soon as possible after having used the reserve supply.

Always return valve to on position after refueling machine.

Scrambler Fuel Valve

Sportsman Fuel Valve

65

CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.

Use only Polaris injection oil. Never substitute or mix oil brands. Serious en- gine damage and voiding of warranty can result.

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

66

CONTROL AND PARTS FUNCTIONS Oil System The oil tank (1) is located under the seat and has a capacity of 12 ounces (1 liter).

To remove the seat, reach under the rear of the cab and pull back on the seat latch. To re- place the seat, set it in place and push down on the rear of seat. Always make sure the seat is locked in place before riding.

1

Do not attempt to release the seat latch unless the machine has not been run for at least an hour. The exhaust gets very hot when the machine is run and can cause serious burns.

67

CONTROL AND PARTS FUNCTIONS

Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Po- laris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.

Enginewarranty coveragemay become void if you use a brand other than Polaris in your machine.

68

CONTROL AND PARTS FUNCTIONS Polaris Premium 2-cycle lubricants are the most advanced formulation of oils spe- cifically designed for todays 2-cycle engines. Months of lab and field tests have resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubri- cants provide additives for 2-cycle engines lacking in todays fuel that keep ring grooves cleaner for less ring sticking and provide improved overall engine cleanli- ness. With new generation lubricity technology, they excel in meeting the lubrica- tion demands of todays high performance 2-cycle engines. These are optimum oils recommended for liquid cooled and air cooled 2-cycle engines. We believe these oils are the best available in the market today.

Premium 2-Cycle Oil

Polaris also has a TC-W3 premium oil available for use in all of our 2 cycle prod- ucts. We highly recommend its use if premium gold synthetic is not used. The only oil recommended for this ATV is Polaris brand oil. Polaris Premium 2-cycle oils will readily mix with each other, however do not mix Polaris Premium 2-cycle oils with any other oils as they may not be compatible and engine damage may occur.

69

CONTROL AND PARTS FUNCTIONS Kick Starter

If the battery is weak and cannot start the en- gine, kick start lever will allow vehicle opera- tion until repairs can be made.

1. Be certain your vehicle is on a level surface and the parking brake is set. See page 58.

2. Fold out the kick start lever (A)which is on the left hand side of the machine.

3. Turn the key to ON and make sure the stop switch is in the RUN position.

4. Placing your foot on the kick start, push your heel downward to crank the engine.

5. Once the engine has started, fold the kickstart lever back into place.

A

70

STARTING THE ENGINE Procedure for Starting a Cold Engine

Indicates a potential hazard which could result in severe injury or death.

Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poi- sonous and can cause severe injury or death. Always start engines outdoors.

You must allow your vehicle adequate warm up time before operating or en- gine damage could result.

71

STARTING THE ENGINE 1. Set the parking brake. 2. Turn the fuel tank valve to ON. 3. Sit on the vehicle. 4. Attach tether strap to machine and wrist. 5. Turn the engine stop switch to RUN. 6. Turn the ignition key to ON. 7. Press the starter button. NOTE: The rear brake lever must be engaged or the en-

gine will not start. 8. Do not press the throttle while starting the engine. 9. Activate the starter for a maximum of five seconds, releasing the button when the

vehicle starts. If engine does not start, release the starter and wait five seconds; then activate the starter for another five seconds. Repeat this procedure until en- gine starts.

After the engine starts, vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.

72

RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protec- tive gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet which meets or exceeds your states safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.

L

L L

L

L

L

73

RIDING GEAR 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or hel- met face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3. Gloves Off-road style gloves with knuckle pads are the best for comfort and protection. 4. Boots The best footwear is a pair of strong over the calf type boots with heels, such as moto-cross boots. 5. Clothing To protect your body, long sleeves and pants should always be worn. Riding pants with kneepads, a jersey and shoulder pads provide the best protection.

74

VEHICLE BREAK-IN PERIOD 2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient per- formance and longer life for the engine. Perform the following procedures careful- ly.

1. Mix 6.4 ounces of injection oil to two gallons of gasoline in a suitable gas can. Fill the fuel tank as outlined on page 65.

2. Fill the oil tank with Polaris injection oil.

Use only Polaris injection oil. Never substitute or mix oil brands. Serious en- gine damage and voiding of warranty can result.

75

VEHICLE BREAK-IN PERIOD

3. Drive slowly at first. Select an areawhich is open and will give you room to familiar- ize yourself with vehicle operation and handling.

4. Vary the throttle positions.

5. Perform regular checks on fluid levels, controls and all important areas on the ve- hicle as outlined earlier on the daily pre-ride inspection checklist found on page 20.

Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can build up and cause damage to close fitted engine parts.

76

VEHICLE BREAK-IN PERIOD

After the break in period the oil injection system provides the necessary engine lubrication without the need for pre-mixed fuel.

After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pump is functioning properly. If the level has not dropped, see your dealer for oil pump bleeding and repeat the pre-mix procedure.

Fill the oil tank when you refuel your ATV. If you dont serious engine damage could result.

77

CARRYING LOADS The Sportsman 90 has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Never exceed the weights specified and never attempt to carry cargo on the Scrambler models.

Correct loading of this vehicle is necessary to maintain proper stability and op- erating characteristics. Overloading or incorrect positioning of the load affects the vehicles turning, stopping distance and stability. Failure to follow loading requirements could cause severe injury or death.

78

CARRYING LOADS

2/3 of Load on Rear Rack

1/3 of Load on Front Rack

Important Safeguards

To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below:

D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO.

D CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on one rack only increases the possibility of vehicle tip over.

79

CARRYING LOADS

D HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill.

D ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unse- cured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

D LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the ve- hicle and creates a less stable operating condition. When cargo loads are carried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

D OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads which cannot be centered, securely fasten load and operate with extra caution.

80

CARRYING LOADS

D EXTREME CAUTION MUST BE USED when operating with loads extend- ing over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn.

D DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.

81

DAILY PRE-RIDE CHECK

You must inspect your ATV each time before riding to ensure it is in proper working order. If proper check is not done, severe injury or death could result.

82

DAILY PRE-RIDE CHECK

Use the following checklist to verify your machine is in proper working order each time you ride.

Item/Inspection Procedure 1. Tires - check condition and pressures

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

3. All brakes - check operation and adjustment.

4. Throttle - check for free operation and closing

5. Brakelight - check for proper operation.

6. Engine stop switch - check for proper function

7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins

83

DAILY PRE-RIDE CHECK 8. Drive chain - condition and slack; refer to drive chain adjustment

9. Air cleaner element - check for dirt; clean or replace

10. Steering - check for free operation noting any unusual looseness in any area

11. Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fas- teners

12. Operators helmet, goggles and clothing

Indicates a potential hazard which could result in severe injury or death.

84

RIDING

85

RIDING 1. Sit upright with both feet on the footrests and both hands on the handlebars.

2. Start the engine and allow it to warm up.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin driving. Vehicle speed is controlled by the amount of throttle opening.

6. Drive slowly, practice maneuvering and using the throttle and brakes on level sur- faces.

86

RIDING Making Turns

87

RIDING Practice making turns at slow speeds. Polaris ATVs are equipped with a solid rear axle which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. To turn, steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer foot- rest. This technique alters the balance of traction between the rear wheels allow- ing the turn to be made smoothly.

Avoid turning at sharp angles. Tipover and severe injury may result.

88

RIDING Riding On Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or dur- ing cold freezing weather, special attention must be paid to prevent vehicle turnover. Always:

89

RIDING 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns

which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your

body weight forward. 4. Never apply brakes during a skid. Complete loss of ATV control can result. 5. Do not operate on excessively slippery surfaces if possible to avoid. 6. Always reduce speed and use additional caution.

Failure to exercise care when operating the ATV on slippery surfaces can be dangerous. Loss of tire traction and vehicle control can result in an accident, including an overturn.

90

RIDING Traveling Uphill

15_ Maximum

91

RIDING

If you have to travel uphill always travel straight uphill and: 1. Avoid steep hills (15_ maximum). 2. Keep both feet on the footrests. 3. Transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Remain alert and be prepared to take emergency action. This may include quick

dismounting of the ATV.

Do not operate this machine on hilly terrain. If you cannot avoid operating in hilly terrain, use extreme caution. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

92

RIDING Sidehilling

93

RIDING Avoid traveling across the side of a hill at all costs. In the event you do enter into a situation where sidehilling is unavoidable, always: 1. Slow down.

2. Lean into the hill transferring your upper bodyweight up hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle directions.

If vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dis- mount on the uphill side immediately!

Improperly crossing hills or turning on hills can be dangerous. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death.

94

RIDING Traveling Downhill

95

RIDING Whenever descending a hill, always: 1. Drive directly downhill.

2. Transfer your weight to the rear of the vehicle.

3. Slow down.

4. Apply the the front and rear brakes at the same time and very slightly to aid in slow- ing.

Do not travel at excessive speeds. It is dangerous and can cause loss of ve- hicle control and tipping, resulting in severe injury or death.

96

RIDING Turning Around On A Hill

8

Uphill

If the ATV stalls while climbing a hill, never back it down the hill! Onemaneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn.

97

RIDING 1. Stop and lock the parking brake while maintaining body weight uphill. 2. Shut off engine. 3. Dismount on left or uphill side of ATV. 4. Staying uphill of ATV, turn handlebars full left (while facing front of ATV). 5. While holding service brake, release parking brake lock and slowly allow ATV to

roll around to your right until ATV is pointing across the hill or slightly downward. 6. Lock the parking brake and remount ATV from the uphill side, maintaining body

weight uphill. 7. Restart engine, release parking brake, and proceed slowly, controlling speed with

the service brake, until ATV is on reasonably level ground.

Avoid climbing steep hills. Loss of vehicle control or overturning of the ATV could occur resulting in severe injury or death.

98

RIDING Crossing Streams

Your Polaris ATV can operate through water up to depths just below the foot- rests. Before fording streams always:

99

RIDING 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible. 4. After crossing, dry the brakes by applying light pressure to the levers until braking

action is normal. If you do not perform this procedure, your brakesmay be ineffec- tive.

D Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, maintain a slow and steady for- ward motion. Do not make sudden turns or stops and do not make sudden throttle changes.

NOTE: If the vehicle is run in water, it is critical the machine is serviced as out- lined in the maintenance chart beginning on page 117. The following areas need special attention: engine oil, transmission oil, front and rear gearcases, and all grease fittings.

100

RIDING Trail Obstacles

101

RIDING Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches.

Not all obstacles are visible. Travel with caution on trails. severe injury or death can result if your machine comes in contact with a hidden obstacle.

Indicates a potential hazard which could result in severe injury or death.

102

RIDING Parking on an Incline

103

RIDING Whenever the Vehicle is Parked 1. Turn the engine off.

2. Set the parking brake.

3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above.

4. Shut off fuel supply.

104

PVT SYSTEM OPERATION PVT System

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the follow- ing responsibilities to make sure this system remains safe: D Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at high speeds. This system has been precision balanced. Any modification will cause the system to be out of bal- ance, creating vibration and additional loads on components.

D Routine maintenance is the responsibility of the owner. Always follow rec- ommended maintenance procedures. See your dealer!

D This PVT system is intended for use on Polaris products only. D The PVT housing must be securely in place during operation.

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

105

PVT SYSTEM OPERATION

If the vehicle is operated in dusty areas, it will be necessary to clean the filter more often. To clean the PVT filter: 1. Remove the screws and the crankcase cover. 2. Remove the screws and the filter cover. 3. Soak the filter in a mild detergent and rinse with clean water. 4. Allow the filter to air dry and reinstall it.

If your vehicle is operated in salt water areas, it must be rinsed with fresh water to prevent corrosion that can be caused by exposure to seawater.

106

BATTERY Battery

Only adults should ever touch the battery. Never allow children to handle a battery or service a battery in any way.

Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could result causing serious injury or death.

107

BATTERY

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of mag- nesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

108

BATTERY

Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

Maintain between upper and lower level marks

109

BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and battery in position. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable next. 4. Lift the battery out of the ATV, being careful not to tip it sideways and spill electro-

lyte.

If electrolyte spills, immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the ATV.

Indicates a potential hazard which could result in severe injury or death.

110

BATTERY

Battery Installation and Connections

Battery terminals and connections should be kept free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean rags. Coat the terminals with dielectric grease or pe- troleum jelly. Be careful not to allow cleaning solution or tap water into the battery.

To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death.

111

BATTERY 1. Set the battery in its holder. 2. First connect and tighten the red (positive) cable. 3. Second connect and tighten the black (negative) cable. 4. Attach the hold down strap. 5. Verify that cables are properly routed.

NOTE:

D When your ATV is placed in storage for three months or more, the battery should be removed, charged to proper level, and stored in a cool dry place.

D Before reusing, take the battery to your dealer for testing and recharging.

D When installing a new battery, make certain it is fully charged prior to its initial use. Using a battery that is not fully charged can damage the battery resulting in a shorter life of the battery. It can also hinder vehicle performance.

112

NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!

U.S. Federal law prohibits the following acts or the causing thereof:

(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorpo- rated into any new vehicle for the purpose of noise control prior to its sale or deliv- ery to the ultimate purchaser or while it is in use or

(2) the use of the vehicle after such device or element of design has been re- moved or rendered inoperative by any person.

ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BE- LOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING: 1. Removal or alteration or the puncturing of the muffler or any engine component

which conducts removal of engine exhaust gases.

113

NOISE EMISSION CONTROL SYSTEM REGULATION

2. Removal or alteration or the puncturing of any part of the engine air induction sys- tem.

3. Replacement of any vehicle parts with parts not in compliance with federal regula- tions.

4. Lack of proper maintenance.

CAUTION: Remember, exhaust system components are very hot during and after use of ATV.

D Do not touch exhaust system components. Serious burns can result.

D Be especially careful when traveling through tall grass. The potential for fire ex- ists.

114

NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor

Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A.

115

MAINTENANCE

Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are:

2-cycle engines D spark plug wrench with Phillips head screwdriver

D tire pressure gauge

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest, most reli- able condition. Inspection, adjustment and lubrication intervals of important com- ponents are explained in the following chart on the following pages.

116

MAINTENANCE Maintenance intervals are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment proce- dures, have a qualified dealer perform these operations. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

117

MAINTENANCE " More often under severe use, such as dirty or wet conditions

Item Hours or Miles

When Remarks

Brake System Pre-ride Pre-ride Pre-ride inspection item

Tires Pre-ride Pre-ride Inspect daily, pre-ride inspection item

Wheels Pre-ride Pre-ride Pre-ride inspection item

Frame nuts, bolts, fasteners

Pre-ride Pre-ride Pre-ride inspection item

Oil Level Daily Daily Check when refueling

" Air Filter Daily Daily Inspect-Clean

J Brake pad wear 10 hrs/100 miles

Monthly Inspect periodically

Battery 20 hrs Monthly Check Terminals/clean/check fluid level

118

MAINTENANCE Periodic Maintenance Schedule (Cont.)

" More often under severe use, such as dirty or wet conditions

Item Hours or Miles

When Remarks

Oil Pump Cable 50 hrs 6 months Inspect, adjust, lubricate, replace if re- quired

Carburetor Float Bowl

50 hrs 6 months Drain bowl periodically and prior to storage

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

119

MAINTENANCE Item Hours

or Miles

When Remarks

J Throttle Cable/ ETC Switch

50 hrs 6 months Inspect-adjust, lubricate, replace if neces- sary; pre-ride inspection item

" Steering 50 hrs 6 months Inspect daily, lubricate

" Rear Axle 50 hrs 6 months Inspect bearings, Lube

" Front Suspension 50 hrs 6 months Inspect--lubricate, tighten fasteners

" Rear Suspension 50 hrs 6 months Inspect, tighten fasteners

" Drive Chain 50 hrs 6 months Inspect daily, adjust and lubricate if need- ed

J Clutches (drive and driven)

100 hrs 12 months

Inspect, clean

120

MAINTENANCE

" More often under severe use, such as dirty or wet conditions

Item Hours or Miles

When Remarks

Engine Mounts 100 hrs 12 months Inspect

Spark Plug 100 hrs 12 months Inspect--replace if necessary

J Ignition Timing 100 hrs 12 months Inspect and adjust as needed

Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer.

121

MAINTENANCE Item Hours

or Miles

When Remarks

J Fuel System 100 hours

12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Re- place lines every two years.

J Fuel Filter 100 hrs 12 months Replace annually

Spark arrestor 100 hrs 12 months Clean out

J Front wheel bear- ings

300 hrs 36 months Inspect, replace if necessary

J Idle Speed As Re- quired

As Re- quired

Adjust

J Toe adjustment As re- quired

As re- quired

Periodic inspection, adjust when parts are replaced

122

MAINTENANCE Lubrication Recommendations

Item Lube Rec. Method Frequency*

1. Engine Oil Polaris Injection Oil

Fill oil tank. See page 63. As needed, when refueling

2. Transmission Oil Polaris Premium Synthetic gear case lube

See Page 146 Change annually or at 100 hours

123

MAINTENANCE Lubrication Recommendations

Operating Range

2. Transmission (plug)

124

MAINTENANCE

3. Drive Chain O-Ring chain lube or SAE 80/90

Lubricate as often as re- quired. Before each ride in wet conditions

As required

4. Front A-Arm L Grease ** Locate fittings and grease Every 3 months or 50 hours

L More often under severe use, such as wet or dusty conditions.

**Polaris Premium all Season Grease or grease conforming to NLGI No. 2, such as Conoco Superlube M or Mobilegrease Special. + Grease every 40 hours or approximately 500 miles, or after submerging in water or before long periods of storage or after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.). When suspension action becomes stiff or after washing.

125

MAINTENANCE NOTE: Hours are based on 10 mph average.

4.

126

MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work:

Maintenance Interval Performed

Servicing Date

Servicing Dealer

or Person

Remarks

First 5 Hrs.

25 Hrs.

50 Hrs.

75 Hrs.

100 Hrs.

127

MAINTENANCE

Maintenance Interval Performed

Servicing Date

Servicing Dealer

or Person

Remarks

128

MAINTENANCE

Handlebar Adjustment

Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On models with a headlight pod, it will be necessary to

remove the upper headlight pod. On other models remove the handlebar cover.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handle- bars, resulting in loss of control and possible serious personal injury or death.

129

MAINTENANCE 2. Loosen the four bolts. 3. Adjust handlebar to desired height.

Be sure handlebarsdo not hit gas tank or any other part of machine when turned fully to left or right.

4. Torque handlebar adjuster block bolts to 7.3 ft. lbs.

NOTE: Tighten bolts so there is an equal gap at the front and rear of the handlebar block. Improper gap will re- sult in improper fit of upper pod.

130

MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications

Specification

Front Spindle Nuts 43 ft. lbs

Rear Spindle Nuts 80 ft. lbs.

NOTE: All nuts that have a cotter pin installed must be serviced by an autho- rized Polaris Dealer.

Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component op- erations. Service work must be performed by your authorized Polaris dealer.

131

MAINTENANCE Rear Spring Adjustment

The rear shock absorber spring is ad- justed by rotating the adjuster in the direction required to increase or decrease spring tension.

Rear Spring Adjustment Cam

132

MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation. If the vehicle is rid- den in wet or dusty conditions, clean the filter more often.

Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine.

133

MAINTENANCE

To clean the filter: 1. Remove the screws on

the airbox (A) and re- move the filter (B).

2. Soak the filter in a mild detergent and rinse it in clean water.

3. Let the filter air dry and reinstall in the air box.

A

B

134

MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable.

Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments.

135

MAINTENANCE

Throttle Stop System

This vehicle is equipped with a throttle stop system that controls how far the throttle opens. Using this feature, adults can limit how fast the machine will travel. To adjust, loosen the jam nut (D) Turn the screw (E) inward to re- duce speed and outward to in- crease speed. Tighten jam nut after adjusting.

D E

136

MAINTENANCE Toe Alignment

You can check the toe alignment of the vehicle using the following method. The recommended toe alignment is 1/8 to 1/4 (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1. Set the handlebars in a straight ahead position and hold them in this position. NOTE: The steering frog can be used as an indicator of whether the handle- bars are straight. The frog should al- ways point straight back from the steering post.

137

MAINTENANCE Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side ofmachine and goesaround the stands in front of the machine.

4. Measure from string to rim at front and rear of front rim. Rear rim measure- ment should be 1/16 - 1/8 (.2 to .3 cm) more than front rim measurement.

5. If this measurement needs to be adjusted, contact your dealer for service.

138

MAINTENANCE Brake Adjustment

Periodically check the freeplay of the front and rear brakes. Refer to the chart below for the acceptable range of free- play for your machine.

To adjust the front brake, turn the adjust- ment knob (A) until the freeplay is accept- able.

A

139

MAINTENANCE

To adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is at- tained.

B

140

MAINTENANCE

Brake Freeplay Adjustment

Model Front Rear

Sportsman 90 .39 - .78 10 mm - 20 mm

.39 - .78 10 mm - 20 mm

Scrambler 90 .39 - .78 10 mm - 20 mm

.39 - .78 10 mm - 20 mm

Scrambler 50 .1 - .39 2.5mm - 9.9 mm

.15 - .30 3.8mm - 7.6mm

141

MAINTENANCE

Throttle Cable Adjustment

Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept bet- ween 1/16 and 1/8 (1.5mm - 3.2mm) (C). If adjustment is re- quired, turn the adjustment nut (D) until the freeplay falls in to the ac- ceptable limit.

Indicates a potential hazard which could result in severe injury or death.

C

D

142

MAINTENANCE Spark Plugs The spark plug required for this machine is NGK BP7HS or NGK BPR7HS. Incor- rect spark plug gap can cause the spark plugs to foul. The spark plug gap should be between 0.6 - 0.7 mm. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color. 1. Normal The insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion adjustments.

143

MAINTENANCE 2. Wet Fouled The insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Gener- al causes are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect carburetion adjustments.

144

MAINTENANCE Spark Plug Removal and Replacement

The spark plug is removed by using the special wrench provided in the tool pouch. Remove the spark plug cap and then the spark plug by rotating counterclockwise. Reverse the procedure for spark plug installation. Torque to 17 ft. lbs. Never deviate from the recommended spark plug as engine damage can occur.

Never attempt to remove a spark plug while the engine is warm. The exhaust system or engine could burn you causing severe injury.

145

MAINTENANCE

Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours.

Indicates a potential hazard which could result in severe injury or death.

146

MAINTENANCE Transmission Lubrication The transmission dipstick (A) is located on the top of the transmission. The transmission lubricant level should be checked monthly. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubri- cant (PN 2871478).

A

147

MAINTENANCE

Transmission Oil Changing Procedure 1. Remove fill plug/dipstick. 2. Remove transmission drain plug and drain the oil. Catch and discard used oil prop-

erly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle)

to full mark on the fill plug/dipstick. 5. Check for leaks.

148

MAINTENANCE

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death.

Follow the safeguards listed below to prevent this type of situation.

149

MAINTENANCE

Important Safeguards

Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability.

Do not use improper tires. The use of non-standard size or type tires may affect ATV handling.

Make certain the wheels are installed properly. If wheels are improperly installed it could affect vehicle handling and tire wear.

Wheel Removal Procedure 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the wheel.

150

MAINTENANCE

Wheel Size PSI Wheel Nut Torque

Scrambler 50 Front 16 x 8 - 7 2 22 ft. lbs Rear 16 x 8 - 7 2 22 ft. lbs

Scrambler 90 Front 18 x 7 - 7 2 22 ft. lbs Rear 18 x 7 - 7 2 22 ft. lbs

Sportsman 90 Front 19 x 7 - 8 2 22 ft. lbs Rear 18 x 9.5 - 8 2 22 ft. lbs

151

MAINTENANCE

Wheel Installation 1. With the park brake locked, place the wheel in the correct position on the wheel

hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.

2. Attach the wheel nuts and finger tight- en them.

3. Lower the vehicle to the ground. 4. Securely tighten the wheel nuts ac-

cording to the chart found on page130:

152

MAINTENANCE

Tire Inspection

When replacing a tire always use original equip- ment size and type.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8 (.3 cm) (1) or less.

1

153

MAINTENANCE

Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller.

Regularly lubricate the drive chain with SAE 80-90 lube or an approved O-ring chain spray lube.

Never wash the chain with a high pressure washer or gasoline. Damage to the O-rings will result, causing premature wear and drive chain failure.

Indicates a potential hazard which could result in severe injury or death.

154

MAINTENANCE

Drive Chain Inspection and Adjustment (Cont.)

The adjuster stud must be held secure when tightening jam nuts or the stud may break.

155

MAINTENANCE Rear Drive Chain Slack Adjustment

The normal chain slack should be kept between .40 - .80 10-20 mm) (A).

Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result.

1

A

156

MAINTENANCE

Adjustment Procedure 1. Loosen 4 rear housing mount bolts (A). 2. Tighten chain adjuster (B) to reduce

slack to recommended setting. (.4 - .8 / 10 mm - 20 mm)

3. Tighten jam nuts on chain adjuster. 4. Tighten the four rear housing mount

bolts.

A B

157

MAINTENANCE Brakelight Lamp Replacement

If the brakelight does not work the lamp may need to be replaced. 1. From the rear of the brake light remove two

screws (A)holding lens cover in place and remove lens cover (B).

2. Remove lamp (C) and replace it with recom- mended lamp.

3. Test the brakelight to see that its working. 4. Reinstall the lens cover removed in step 1.

A

B

C

158

MAINTENANCE Cleaning Your ATV

Keeping your ATV clean will not only improve its appearance but it can also ex- tend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile.

Washing

If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmission seals, body panels, brakes and warning labels. Many expensive repair bills can result from using high pressure detergent systems.

NOTE: If a high pressure car wash is used, grease all zerk fittings immediately after washing. Also run the vehicle to evaporate any water that might have en- tered the engine or exhaust system.

159

MAINTENANCE

The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning labels are damaged, contact your a Polaris dealer for free replacement.

Waxing

Your ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use of harsh cleaners since they can scratch the body finish.

Certain products, including insect repellants and chemicals, will damage plas- tic surfaces. Care must be taken when using these products near plastic sur- faces.

160

MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off. 2. Be certain the fuel cap, oil cap, and seat are installed correctly. 3. Always tie the frame of the ATV to the transporting unit securely using suitable

straps or rope. 4. Always lock the parking brake.

161

MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain ad- justments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its power for each 1000 foot (304.8 m) increase in elevation. Although this power cannot be regained, changes to the carburetor and drive sys- tem can be made to allow efficient operation. These changes include: 1. Carburetor re-jetting to compensate for altitude and/or temperature changes. 2. Transmission convertor modification to adjust for engine horsepower loss during

high altitude operation. Contact your dealer. 3. On 2 cyclemodels, air screw adjustments can bemade to compensate for temper-

ature changes and/or changes in altitude.

NOTE: Contact your dealer for altitude adjustments. They have the training and special tools required to perform all necessary modifications for you.

162

SPECIFICATIONS

Specifications - Scrambler 50

Rider Capacity 1

Displacement 49cc

Cooling Fan Cooled

Engine type 2-Stroke

Lubrication Oil Injected

Oil Capacity 1.1 quarts (1 liter)

Fuel Capacity 1.3 gallons (5 liters)

Starting Electric with kick-start backup

Transmission Automatic CVT

Front Suspension A-Arm with 2 (5 cm) of travel

Rear Suspension Spring over shock with 2 (5 cm) of travel

163

SPECIFICATIONS

Specifications - Scrambler 50

Front/Rear Brakes Drum

Parking Brake Mechanical Lock

Front and Rear Tires / PSI 16 x 8-7 (2psi)

Turning Radius 74.8 (190 cm)

Wheel Base 35.4 (90 cm)

Dry Weight 211.6 lbs (96 kgs)

Length 54.6 (138.7 cm)

Width 34 (86.3 cm)

Height 34.7 (88.2 cm)

Brake Light Standard

Low Oil Light Standard

164

SPECIFICATIONS

Specifications - Scrambler 90

Rider Capacity 1

Displacement 89cc

Cooling Fan Cooled

Engine type 2-Stroke

Lubrication Oil Injected

Oil Capacity 1.1 quarts (1 liter)

Fuel Capacity 1.3 gallons (5 liters)

Starting Electric with kick-start backup

Transmission Automatic CVT

Front Suspension A-arm with 2 (5 cm) of travel

Rear Suspension Spring over shock with 2 (5 cm) of travel

165

SPECIFICATIONS

Specifications - Scrambler 90

Front/Rear Brakes Drum

Parking Brake Mechanical Lock

Front and Rear Tires / PSI 18 x 7 - 7 (2psi)

Turning Radius 98.4 (250 cm)

Wheel Base 35.4 (90 cm)

Dry Weight 233.7 lbs (106 kgs)

Length 56.1 (142.4 cm)

Width 34 (86.3 cm)

Height 36.1 (91.8 cm)

Brake Light Standard

Low Oil Light Standard

166

SPECIFICATIONS

Specifications - Sportsman 90

Rider Capacity 1

Displacement 89cc

Cooling Fan Cooled

Engine type 2-Stroke

Lubrication Oil Injected

Oil Capacity 1.1 qts. (1 ltr)

Fuel Capacity 1.3 ga. (5 ltr)

Starting Electric with kick-start backup

Transmission Automatic CVT

Front Suspension A-arm with 2 in / 5 cm of travel

Rear Suspension Spring over shock with 2 in / 5 cm of travel

167

SPECIFICATIONS

Specifications - Sportsman 90

Front/Rear Brakes Drum

Parking Brake Mechanical Lock

Front Tires / PSI 19 x 7 - 8 (2 psi)

Rear Tires / PSI 18 x 9.5 - 8 (2 psi)

Wheel Base 37.8 (96 cm)

Turning Radius 98.4 (250 cm)

Dry Weight 238.1 lbs (108 kgs)

Length 57.6 (146.3 cm)

Width 34.4 (87.4 cm)

Height 36.6 (93 cm)

Brake Light Standard

168

SPECIFICATIONS

Specifications - Sportsman 90

Low Oil Light Standard

Front Rack Capacity 10 lb (4.5 kgs)

Rear Rack Capacity 20 lb (9 kgs)

Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your machine.

169

WIRING DIAGRAM

170

WIRING DIAGRAM

171

TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have.

ENGINE CRANKS BUT FAILS TO START

No Fuel Water in Fuel Spark Plug

Fuel Valve Off Drain System No Spark to Spark Plug

Contact Your Dealer

Clogged Fuel Valve or filter

172

TROUBLESHOOTING

ENGINE STOPS OR LOSES POWER

No Fuel

Contact Your Dealer

Contact Your Dealer

Spark Plug Fouled

Engine Overheated

Clean Engine Exterior

Turn Fuel Valve to Res

Water in Fuel

Air Filter Clogged

Electronic Throttle Control Malfunction

Fuel Vent Line Kinked or Plugged

Clean Radiator screen and Radiator Core (liquid cooled models)

173

WARRANTY

LIMITED WARRANTY

Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects inmaterial or workmanship. Polaris also gives a one year limitedwar- ranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. Thiswarranty is transfer- rable to another consumer during thewarranty period through a Polaris dealer. There is a charge of $35.00 payable to Polaris Industries Inc.

174

WARRANTY

REGISTRATION

At the time of sale, theWarranty Registration Formmust be completed by your dealer and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will record the registration for warranty. THE PURCHASERMUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle- ment. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NOWARRANTY COVERAGEWILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.

Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation. Purchasing a machine in the crate or without proper dealer set--up will void your warranty coverage.

175

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any ATV that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it wasmanufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the ATV due to fire, explosions or any other cause beyond Polaris control.

176

WARRANTY

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warran- ty shall be, at Polaris exclusive option, repair or replacement of any defective materi- als, or components or products. THEREMEDIESSET FORTH IN THISWARRANTY ARETHEONLYREMEDIESAVAILABLETOANYPERSONFORBREACHOFTHIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI- DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED

WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

177

WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OFMERCHANTABILITY AND FITNESS FORA PARTICULARPUR- POSE) ARE LIMITED INDURATIONTO THE ABOVE SIXMONTHWARRANTYPE- RIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requireswarranty service, youmust take it to a Polaris dealer authorized to repairPolaris ATVs. When requesting warranty service youmust present your copyof the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that youuse youroriginal selling dealer; however, youmayuse anyPolaris ServicingDeal- er to perform warranty service.

178

WARRANTY

Please work with your dealer to resolve any warranty issues. Should your dealer re- quire any additional assistance they will contact the appropriate person at Polaris.

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

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

Engine Oil

1. Always use Polaris engine oil.

2. Never substitute ormix oil brands asserious engine damage and voiding ofwarran- ty can result.

179

INDEX AIR CLEANER 132. . . . . . . . . . . . . . . . . . . . . . . . BATTERY INSTALLATION 110. . . . . . . . . . . . . . BATTERY MAINTENANCE 106. . . . . . . . . . . . . . BATTERY REMOVAL 109. . . . . . . . . . . . . . . . . . . Brake Adjustment 138. . . . . . . . . . . . . . . . . . . . . . . Brake Freeplay Adjustment 140. . . . . . . . . . . . . . . Brake Lever R7. . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE PARKING 58. . . . . . . . . . . . . . . . . . . . . . Brakelight Lamp Replacement 157. . . . . . . . . . . . . BRAKES, FRONT 57. . . . . . . . . . . . . . . . . . . . . . . BRAKES, REAR 57. . . . . . . . . . . . . . . . . . . . . . . . Break In Period 74-76. . . . . . . . . . . . . . . . . . . . . . . CAMBER AND CASTER 134. . . . . . . . . . . . . . . . CARBURETOR ADJUSTMENTS 161. . . . . . . . . . CARRYING LOADS 77-80. . . . . . . . . . . . . . . . . . Chain Adjustment 155. . . . . . . . . . . . . . . . . . . . . . . CLEANING YOUR ATV 158. . . . . . . . . . . . . . . . . Control and Parts Functions 49-69. . . . . . . . . . . . . CROSSING STREAMS 98. . . . . . . . . . . . . . . . . . . CYLINDER HEAD TORQUE 145. . . . . . . . . . . . . DAILY PRE-RIDE INSPECTION 20-21, 81-83. . Drive Chain Adjustment 153-154. . . . . . . . . . . . . . ENGINE ELECTRICAL SWITCHES 49. . . . . . . . Engine Start Button 51. . . . . . . . . . . . . . . . . . . . . . . Engine Stop Switch R4, 50. . . . . . . . . . . . . . . . . . .

Front Brake R7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Safety 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 63. . . . . . . . . . . . . . . . . . . . . . . . . Gas Cap R6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL SAFETY AND

DESCRIPTION OF LABELS 5-18. . . . . . . . HANDLEBAR ADJUSTMENT 128. . . . . . . . . . . . Ignition Switch R8. . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR LIGHTS 56. . . . . . . . . . . . . . . . . . . . Kick Starter R5, 69. . . . . . . . . . . . . . . . . . . . . . . . . KNOW YOUR MACHINE R2-R11. . . . . . . . . . . Load Capacity 77-80. . . . . . . . . . . . . . . . . . . . . . . . LUBRICANT, 2 Cycle 67. . . . . . . . . . . . . . . . . . . . LUBRICATION RECOMMENDATIONS 122-123 Main Switch 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery 106-111. . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 115-161. . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE RECORD 126. . . . . . . . . . . . . . MAINTENANCE SCHEDULE 115-118. . . . . . . . MAKING TURNS 86. . . . . . . . . . . . . . . . . . . . . . . NOISE CONTROL SYSTEM 112-114. . . . . . . . . . OIL SYSTEM 63. . . . . . . . . . . . . . . . . . . . . . . . . . . Oil System 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION WARNINGS 19-46. . . . . . . . . . . . . . PARKING ON AN INCLINE 102. . . . . . . . . . . . . .

180

INDEX Pre Operation Check R12-R15. . . . . . . . . . . . . . . . PVT SYSTEM 62, 104. . . . . . . . . . . . . . . . . . . . . . Rear Brake R7. . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SPRING ADJUSTMENT 131. . . . . . . . . . . RIDERS SECTION R1. . . . . . . . . . . . . . . . . . . . . RIDING 84-103. . . . . . . . . . . . . . . . . . . . . . . . . . . Riding Gear 72-73. . . . . . . . . . . . . . . . . . . . . . . . . RIDING ON SLIPPERY SURFACES 88. . . . . . . . . SAFETY WARNING AND

OPERATION DECALS 10. . . . . . . . . . . . . . . SIDEHILLING 92. . . . . . . . . . . . . . . . . . . . . . . . . . SPARK PLUGS 142. . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 162-168. . . . . . . . . . . . . . . . . . STARTING A COLD ENGINE 70. . . . . . . . . . . . . Starting the Engine 70-71. . . . . . . . . . . . . . . . . . . . STEERING INSPECTION 134. . . . . . . . . . . . . . . . Tether Strap R9. . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle R4, 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable Adjustment 135, 141. . . . . . . . . . . . THROTTLE LEVER 54. . . . . . . . . . . . . . . . . . . . . TIRE INSPECTION 152. . . . . . . . . . . . . . . . . . . . .

Toe Alignment 136-137. . . . . . . . . . . . . . . . . . . . . TOOL KIT 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS 130. . . . . . . . . . . . . . TRAIL OBSTACLES 100. . . . . . . . . . . . . . . . . . . . TRANSMISSION LUBRICATION 146. . . . . . . . . TRANSMISSION

OIL CHANGING PROCEDURE 147. . . . . . . TRANSPORTING 160. . . . . . . . . . . . . . . . . . . . . . TRAVELING DOWNHILL 94. . . . . . . . . . . . . . . . TRAVELING UPHILL 90. . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 171-172. . . . . . . . . . . . . . TURNING AROUND ON A HILL 96. . . . . . . . . . UNDERSTANDING WARNINGS 1-4. . . . . . . . . . Understanding Warnings R16-R20. . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 47-48. WARRANTY 173-178. . . . . . . . . . . . . . . . . . . . . . WHEEL INSTALLATION 149-151. . . . . . . . . . . . Wheel Nut Torque 150. . . . . . . . . . . . . . . . . . . . . . WHEEL REMOVAL 149. . . . . . . . . . . . . . . . . . . . WI