Polaris Sportsman 90 User manual

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

Owner’s 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 d eath .

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 engineeringand manufacturing 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 b e 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

AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATVhandles

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 child’s 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 child ren

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 o n 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 havethe ATVchecked by an authorized Polaris dealerif 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-

sivelyslippery or loose surfaces. Shift your weight 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 have mastered 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 brakes may have reduced stopping ability. Test your brakes after leaving water.

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. Always maintain proper

tire pressure as described in this manual.

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

• Neverexceed the stated load capacityfor an ATV. Cargo should be properlydistrib-

uted and securely attached. Reduce speed and follow instructions in this manual

for carrying cargo or pulling a trailer. Allow greater distance for braking.

FOR MORE INFORMATION ABOUT ATV 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; or make any other modificationsto the vehicle for these purposes. Any modi-

fications to the original equipment of the ATV substantially increase the risk of bodily

injury. Please be aware that these modifications may 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 followthe 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 d eath .

x

TABLE OF CONTENTS

RIDER’S 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 PAR TS 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...........................................

W ARRANTY 173-178.....................................................

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

R-- 1

RIDER’S 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

child’s 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 m ost 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 don’t,

you could get hurt very badly 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, let’s 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. Throttle Control (A) - This makes 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

2

A

R-- 5

KNOW YOUR MACHINE

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

weak to start your machine, you can

push o n 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 kickstar t on page

69.

3

B

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