Owners Manual
Page 3
... seriously affect handling and control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. WARNING NEVER operate: S without proper training or instruction S at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100...
... seriously affect handling and control ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. WARNING NEVER operate: S without proper training or instruction S at speeds too fast for your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100...
Owners Manual
Page 5
.... POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are provided as translations of the original instructions. No liability can be accepted for this publication is expressly prohibited. Depictions and/or procedures in this publication are in part, is based on the latest product information at the time of publication. Printed in Taiwan 2012 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9923570...
.... POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are provided as translations of the original instructions. No liability can be accepted for this publication is expressly prohibited. Depictions and/or procedures in this publication are in part, is based on the latest product information at the time of publication. Printed in Taiwan 2012 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9923570...
Owners Manual
Page 18
... where refueling is performed or where gasoline is stored. • Do not overfill the tank. Safety Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Never allow a child to refuel or handle gasoline. • Always exercise extreme caution whenever handling gasoline. • Always refuel with soap and water and change clothing. • Turn the fuel valve off whenever the...
... where refueling is performed or where gasoline is stored. • Do not overfill the tank. Safety Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Never allow a child to refuel or handle gasoline. • Always exercise extreme caution whenever handling gasoline. • Always refuel with soap and water and change clothing. • Turn the fuel valve off whenever the...
Owners Manual
Page 36
... DEATH. a collision can result in turns; NEVER operate: without proper training or instruction; with another vehicle; LOCATE AND READ OWNER'S MANUAL. Never carry passengers. at speeds too fast for your skills or the conditions; ALWAYS: use can occur with a passenger passengers affect balance and steering and increase risk of losing control. pavement may seriously affect handling and control. Always use with drugs or...
... DEATH. a collision can result in turns; NEVER operate: without proper training or instruction; with another vehicle; LOCATE AND READ OWNER'S MANUAL. Never carry passengers. at speeds too fast for your skills or the conditions; ALWAYS: use can occur with a passenger passengers affect balance and steering and increase risk of losing control. pavement may seriously affect handling and control. Always use with drugs or...
Owners Manual
Page 48
... body. 45 Tether Switch OUTLAW SPORTSMAN Never ride without the tether strap attached to your right wrist and to your ATV, the tether strap will pull away from the switch and the engine will stop. 10. You can also use this key ...to let the cord get tangled around the handlebars or any part of your ATV. Tether Switch 9. Tether Strap and Switch - Be careful not to turn off your ATV every time you fall off the engine. 10. The ignition switch key must always be turned on before pushing the starter button. Ignition Switch 10. Ignition Switch - If you drive. Ignition Switch...
... body. 45 Tether Switch OUTLAW SPORTSMAN Never ride without the tether strap attached to your right wrist and to your ATV, the tether strap will pull away from the switch and the engine will stop. 10. You can also use this key ...to let the cord get tangled around the handlebars or any part of your ATV. Tether Switch 9. Tether Strap and Switch - Be careful not to turn off your ATV every time you fall off the engine. 10. The ignition switch key must always be turned on before pushing the starter button. Ignition Switch 10. Ignition Switch - If you drive. Ignition Switch...
Owners Manual
Page 61
... in the OFF position. Horn Stop Switch Start Button Choke Lever Choke Lever Use the choke to the entire vehicle. Features and Controls Engine Stop Switch The engine will not start a cold engine. To stop the engine quickly, push the stop switch shut off all electrical power to start or run when the stop switch is to provide the operator with a quick means of stuck throttle or other emergency. Push...
... in the OFF position. Horn Stop Switch Start Button Choke Lever Choke Lever Use the choke to the entire vehicle. Features and Controls Engine Stop Switch The engine will not start a cold engine. To stop the engine quickly, push the stop switch shut off all electrical power to start or run when the stop switch is to provide the operator with a quick means of stuck throttle or other emergency. Push...
Owners Manual
Page 69
Do not use fuel with a minimum pump octane number of 87=(R+ M/2) octane. Use unleaded gasoline with ethanol content greater than 10 percent, such as E-85 fuel. Refer to the specifications section beginning on page 162 for fuel tank capacity. 66 Features and Controls Fuel System Gas Cap Gas Cap The fuel tank filler cap is located directly below the handlebars.
Do not use fuel with a minimum pump octane number of 87=(R+ M/2) octane. Use unleaded gasoline with ethanol content greater than 10 percent, such as E-85 fuel. Refer to the specifications section beginning on page 162 for fuel tank capacity. 66 Features and Controls Fuel System Gas Cap Gas Cap The fuel tank filler cap is located directly below the handlebars.
Owners Manual
Page 70
ON: For normal operation. SPORTSMAN 90 Fuel Valve The reserve setting allows operation for approximately 7-10 miles (11-16 km). Always return the valve to the ON position after using the main supply. RES: For reserve supply if main supply is located on the left side of the ATV. Always refill the gas tank as soon as possible after refueling. OFF OUTLAW 90 Fuel Valve ON RES 67 Features and Controls Fuel Valve The fuel valve is exhausted. It has three settings. OFF: For vehicle storage and when transporting.
ON: For normal operation. SPORTSMAN 90 Fuel Valve The reserve setting allows operation for approximately 7-10 miles (11-16 km). Always return the valve to the ON position after using the main supply. RES: For reserve supply if main supply is located on the left side of the ATV. Always refill the gas tank as soon as possible after refueling. OFF OUTLAW 90 Fuel Valve ON RES 67 Features and Controls Fuel Valve The fuel valve is exhausted. It has three settings. OFF: For vehicle storage and when transporting.
Owners Manual
Page 71
... position. 6. Features and Controls Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is provided in the tool kit for removing or installing the lever. Shift the transmission to ON. Fold out the kick-start lever back into place. 68 Tip: A 10/12mm wrench is serviced. 1. Turn the key to neutral. 3. If...
... position. 6. Features and Controls Kick-Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is provided in the tool kit for removing or installing the lever. Shift the transmission to ON. Fold out the kick-start lever back into place. 68 Tip: A 10/12mm wrench is serviced. 1. Turn the key to neutral. 3. If...
Owners Manual
Page 79
... warm up to the left . Shift the transmission to your wrist. 5. Operation Starting the Engine NOTICE: Operating the ATV immediately after starting . 6. Attach the tether strap to the ATV and to neutral. The choke is off when the lever is...vehicle. Turn the fuel valve on when the lever is cold, use of the choke. If the engine is pushed completely to the ON position. 76 Push the engine stop switch up for starting could cause engine damage. A warm engine will not require the use full choke by pushing the choke lever all the way to the right. Lock the parking brake...
... warm up to the left . Shift the transmission to your wrist. 5. Operation Starting the Engine NOTICE: Operating the ATV immediately after starting . 6. Attach the tether strap to the ATV and to neutral. The choke is off when the lever is...vehicle. Turn the fuel valve on when the lever is cold, use of the choke. If the engine is pushed completely to the ON position. 76 Push the engine stop switch up for starting could cause engine damage. A warm engine will not require the use full choke by pushing the choke lever all the way to the right. Lock the parking brake...
Owners Manual
Page 81
Apply the brakes until the vehicle stops moving. Lock the parking brake. 6. Operation Stopping the Engine 1. 2. 3. 4. Stop the engine. To avoid draining the battery, always turn the key to neutral. Shift the transmission to the OFF position when the engine is not running. 78 There are three ways to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. 5. Release the throttle completely.
Apply the brakes until the vehicle stops moving. Lock the parking brake. 6. Operation Stopping the Engine 1. 2. 3. 4. Stop the engine. To avoid draining the battery, always turn the key to neutral. Shift the transmission to the OFF position when the engine is not running. 78 There are three ways to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. 5. Release the throttle completely.
Owners Manual
Page 100
... other adjustments should review the limitations of this vehicle are controlled by an authorized POLARIS dealer. The engine and related components must be performed by engine design, including factory-set fuel delivery and ignition. Electromagnetic Interference This spark ignition system complies with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should be maintained at POLARIS specifications to this vehicle. 97
... other adjustments should review the limitations of this vehicle are controlled by an authorized POLARIS dealer. The engine and related components must be performed by engine design, including factory-set fuel delivery and ignition. Electromagnetic Interference This spark ignition system complies with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should be maintained at POLARIS specifications to this vehicle. 97
Owners Manual
Page 107
... often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours E E Carburetor air intake ducts/flange Drive belt Brake pad wear Fuel system 50 50 50 100 Calendar 6M 6M 6M 12 M Miles (Km) 500 (800) 500 (800) 500 (800) 1000 (1600) Check for proper sealing/air leaks See your POLARIS dealer See your POLARIS dealer Check for vehicles subjected to...
... often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours E E Carburetor air intake ducts/flange Drive belt Brake pad wear Fuel system 50 50 50 100 Calendar 6M 6M 6M 12 M Miles (Km) 500 (800) 500 (800) 500 (800) 1000 (1600) Check for proper sealing/air leaks See your POLARIS dealer See your POLARIS dealer Check for vehicles subjected to...
Owners Manual
Page 111
... Conditions Outside air temperature is above 32 F/0 C Outside air temperature is not used. Oil may need to be changed more frequently if POLARIS oil is below 32 F/0 C Use This Recommended Oil POLARIS Synthetic Youth Oil (or Synthetic SAE40) Semi-Synthetic 20W-40 NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use automotive oil. Maintenance Engine Oil Oil...
... Conditions Outside air temperature is above 32 F/0 C Outside air temperature is not used. Oil may need to be changed more frequently if POLARIS oil is below 32 F/0 C Use This Recommended Oil POLARIS Synthetic Youth Oil (or Synthetic SAE40) Semi-Synthetic 20W-40 NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use automotive oil. Maintenance Engine Oil Oil...
Owners Manual
Page 167
Specifications SPORTSMAN 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 1 Rider/180 lbs. (81.7 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 2 gallons (7.7 liters) .22 gallons (.85 liters) Electric with kick-start backup Automatic CVT Chain Single A-arm with 5" (12.7 cm) of travel Swing arm with 6" (15.2 cm) of travel 164
Specifications SPORTSMAN 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 1 Rider/180 lbs. (81.7 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 2 gallons (7.7 liters) .22 gallons (.85 liters) Electric with kick-start backup Automatic CVT Chain Single A-arm with 5" (12.7 cm) of travel Swing arm with 6" (15.2 cm) of travel 164
Owners Manual
Page 184
... may not be covered by warranty. however, you must take it to a POLARIS dealer authorized to perform warranty service. If any POLARIS Servicing Dealer to repair POLARIS ATVs. When requesting warranty service you may cause engine damage. Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must present your copy of state or federal law, all other rights which vary from the use of POLARIS engine oil. 2.
... may not be covered by warranty. however, you must take it to a POLARIS dealer authorized to perform warranty service. If any POLARIS Servicing Dealer to repair POLARIS ATVs. When requesting warranty service you may cause engine damage. Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must present your copy of state or federal law, all other rights which vary from the use of POLARIS engine oil. 2.
Owners Manual
Page 185
...Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. How to Get Service In the country where your vehicle was purchased, Warranty or Service Bulletin repairs... dealer to vehicles that have any authorized POLARIS dealer who sells the same line as your vehicle was purchased: Warranty or Service Bulletin repairs must be requested from POLARIS Industries. Dealers may be done by an authorized POLARIS dealer. If...
...Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. How to Get Service In the country where your vehicle was purchased, Warranty or Service Bulletin repairs... dealer to vehicles that have any authorized POLARIS dealer who sells the same line as your vehicle was purchased: Warranty or Service Bulletin repairs must be requested from POLARIS Industries. Dealers may be done by an authorized POLARIS dealer. If...
Owners Manual
Page 189
... considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector...
... considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units The following parts are considered emission-related components for evaporative emissions: Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector...
Owners Manual
Page 196
... ...81 Driving on a Sidehill ...86 Driving on Slippery Surfaces . 82-83 C Declaration of Conformity ...174 Driving Over Obstacles ...91 Driving Procedure ...79 Driving Through Water ...92-93 Driving Uphill ...84-85 Electronic Throttle Control ...61 Emission Control Systems ...96-97 Engine Start Button ...59 Engine Stop Switch ...58 Equipment Modifications ...12 Exhaust, Exposure to ...15 Eye Protection ...11 Fuel Filter ...113 Fuel Safety ...15 Fuel Stabilizer ...158 Fuel System ...66 Fuel Valve ...67...
... ...81 Driving on a Sidehill ...86 Driving on Slippery Surfaces . 82-83 C Declaration of Conformity ...174 Driving Over Obstacles ...91 Driving Procedure ...79 Driving Through Water ...92-93 Driving Uphill ...84-85 Electronic Throttle Control ...61 Emission Control Systems ...96-97 Engine Start Button ...59 Engine Stop Switch ...58 Equipment Modifications ...12 Exhaust, Exposure to ...15 Eye Protection ...11 Fuel Filter ...113 Fuel Safety ...15 Fuel Stabilizer ...158 Fuel System ...66 Fuel Valve ...67...
Owners Manual
Page 198
... ...26 Using Alcohol or Drugs ...17 S Safety Words and Symbols ...6 Seat Latch ...43 Severe Use ...99 Shift Lever ...42, 62 Shock Spring Adjustment ...136 Sidehilling ...86 Signal words ...6 Spark Arrester ...122-123 Spark Plug Change ...117 Spark Plugs ...116-117 Specifications OUTLAW 90 ...162-163 SPORTSMAN 90 ...164-165 Speed Control System ...126-127 Start Button ...59 Starting the Engine ...76-77 Steering Inspection ...136 Stop Switch ...58 Stopping the ATV ...46 Stopping the...
... ...26 Using Alcohol or Drugs ...17 S Safety Words and Symbols ...6 Seat Latch ...43 Severe Use ...99 Shift Lever ...42, 62 Shock Spring Adjustment ...136 Sidehilling ...86 Signal words ...6 Spark Arrester ...122-123 Spark Plug Change ...117 Spark Plugs ...116-117 Specifications OUTLAW 90 ...162-163 SPORTSMAN 90 ...164-165 Speed Control System ...126-127 Start Button ...59 Starting the Engine ...76-77 Steering Inspection ...136 Stop Switch ...58 Stopping the ATV ...46 Stopping the...