2004 Polaris Sportsman 90 Problems and Repair Information
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Free 2004 Polaris Sportsman 90 manuals!
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Popular 2004 Polaris Sportsman 90 Manual Pages
Owners Manual - Page 2
WARNING
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
Owners Manual - Page 3
...ATV safely. Never allow a child to operate the ATV without adult supervision. We've provided this manual. Help your children learn to show respect for our environment and for assistance.
1 Help them ...Way Out experience along with safety as a top priority. Always supervise your child's use of the vehicle, be able to operate an ATV safely. If you determine that all of your new ATV. ...
Owners Manual - Page 5
... you don't understand, and pay close attention to the warnings and instructions you read your manual, and then enjoy riding your new Polaris ATV!
3 Your safety and the safety of the...enjoy riding your new ATV, and that you need to read and understand the information in your owner's manual. As the driver of others is the most important thing to keep yourself and those around you safe...
Owners Manual - Page 7
...
Adult Section ...33 Safety Decals ...34 Driver Warnings ...47 Vehicle ID Numbers ...74 Features and Controls . . 77 Break-in Period ...92 Pre-Ride Inspections ...94 Starting the Engine ...96 Driving Safely ...98 Hauling Cargo ...115 Emission Control ...119 Maintenance ...120 Specifications ...164 Polaris Products ...170 Troubleshooting ...172 Warranty ...178 Index ...184
Table of Contents
5
Owners Manual - Page 9
... allow a younger child to ride an ATV.
Read the owner's manual with them periodically afterwards. Safety Training
When you were provided with your... operators understand all aspects of ATV safety. In addition, you purchased this ATV, your children before starting the engine for your child on a regular basis. Know Your ATV Before Riding
Parents must help their children learn the ...
Owners Manual - Page 10
... these words and symbols are used. Become familiar with their meanings before reading the manual.
WARNING
The safety alert warning indicates a potential hazard that may result in this manual and on your vehicle. The safety alert symbol, on your vehicle or in serious injury or death.
8 Safety
The following signal words and symbols appear...
Owners Manual - Page 12
Safety
WARNING
Failure to follow the warnings in this manual can be hazardous to take proper precautions. A Polaris ATV is not a toy and can result in ... driving on hills or over obstacles, if you fail to operate. Read and understand the owner's manual and all warnings before operating a Polaris ATV.
10 This vehicle handles differently than other vehicles such as motorcycles and cars.
Owners Manual - Page 17
...tire pressure as described in this manual. If necessary apply them lightly several times to prevent unauthorized use to let friction dry out the pads. S Always remove the ignition key when the vehicle is not in use or accidental starting. S Always use of accessories...Avoid operating the ATV through improper installation or use the size and type tires specified in this manual.
Owners Manual - Page 28
...you can ride your ATV safely. Never start the engine if your ATV. You could be seriously hurt if...brakes.
This must read the instructions and warnings on page 86 of this manual.
Have an adult or your ATV has sticky brakes. Children must be ...stay close to your ATV needs more gas. Check the brake levers by an adult. Always have an adult put gas in your ATV has sticky brakes....
Owners Manual - Page 45
... seat)
43 Factory Setting: 40° to 27° C.
See your Owner's Manual. at 0-3000 feet. (5° to 80° F. S Specific carburetor jetting and adjustments are required depending on rear of this vehicle without the filter element will severely damage the engine. at 0-900 meters)
(on air filter box)
4
(on temperature and altitude. S Clean...
Owners Manual - Page 67
... the rear brake as well, and then lock the parking brake. Apply the front brake slowly. Never apply engine power. Turn the ATV around and remount, following the procedure described in the Owner's Manual. If you lose all forward speed: Keep your weight uphill. If you begin rolling backwards: Keep weight uphill...
Owners Manual - Page 82
Failure to severe injury or death. Always check the lever for service if throttle problems arise. Also check occasionally during operation. Always contact your dealer for free movement and return before starting the engine. Features and Controls
Throttle Controls
4
WARNING
Operating an ATV with a sticking or improperly operating throttle. Never start or operate an...
Owners Manual - Page 86
... apply the throttle to warm the engine will make the machine move forward.
84 Features and Controls
Brakes
Parking Brake
NOTE: This vehicle has a PVT system that's always in forward gear, activating the throttle to move forward if the park brake is not locked. Since the transmission is left unattended. Always lock the...
Owners Manual - Page 110
...manual. Avoid climbing steep hills (15_ maximum). One maneuver that can be used when it down the hill! Stop and lock the parking brake while maintaining body weight uphill. 2. Driving Safely
Turning Around on a Hill
WARNING
Improper hill climbing procedures could cause loss of the vehicle..., or on the left if the vehicle is the K-turn: 1.
Shut off the engine. 3. Use...
Owners Manual - Page 162
.... Washing the ATV
The best and safest way to the wheel bearings, transmission seals, body panels, brakes and warning labels. NOTE: If warning and ... have entered the engine or exhaust system.
160 NOTE: Grease all zerk fittings immediately after washing, and allow the vehicle to run for ...and a pail of a high pressure type car wash system for free replacement. Use a professional type washing mitten, ...
Owners Manual - Page 175
...
Low battery voltage Loose battery connections Loose solenoid connections
Solution
Recharge battery with .5 amp charger Check all connections and tighten Check all connections and tighten
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range
Solution
Replace with recommended...
Owners Manual - Page 176
Troubleshooting
Engine Backfires
Possible Cause
Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure
Solution
Inspect, clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel See your Polaris dealer...
Owners Manual - Page 177
...
Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery with .5 amp charger Inspect and replace Replace with recommended fuel Inspect and clean or replace See your Polaris dealer See your Polaris dealer
175
Owners Manual - Page 179
... air filter Electronic throttle control malfunction Other mechanical failure
Solution
Turn fuel valve to reserve, refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery with .5 amp charger Replace with...
Owners Manual - Page 183
... in effect. If any Polaris Servicing Dealer to perform warranty service. When requesting warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs. Should your dealer require any warranty issues.
Warranty
HOW TO OBTAIN WARRANTY SERVICE
If your ATV requires warranty service, you must present your copy of the Warranty Registration form to the dealer...
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