Owners Manual
Page 3
... Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922475 Rev 02 Printed in turns S avoid paved surfaces - FOLLOW ALL INSTRUCTIONS AND WARNINGS. pavement may 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...
... Polaris Sales Inc., 2100 Hwy 55 Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922475 Rev 02 Printed in turns S avoid paved surfaces - FOLLOW ALL INSTRUCTIONS AND WARNINGS. pavement may 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...
Owners Manual
Page 5
...information contained within , whether whole or in part, is based on the latest product information at the time of Polaris Industries Inc. Depictions and/or procedures in the design and quality of the depictions and/or procedures contained.... Copyright 2009 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in USA 2010 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9922475 2 POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are...
...information contained within , whether whole or in part, is based on the latest product information at the time of Polaris Industries Inc. Depictions and/or procedures in the design and quality of the depictions and/or procedures contained.... Copyright 2009 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of production components, some minor discrepancies may result between the actual vehicle and the information presented in USA 2010 OUTLAW 90/SPORTSMAN 90 Owner's Manual P/N 9922475 2 POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are...
Owners Manual
Page 36
... skills or the conditions; Never use an approved helmet and protective gear. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376 + 33 avoid paved surfaces - Never carry passengers. pavement may seriously affect handling and control. LOCATE AND READ OWNER'S MANUAL. Always use on public roads - on public roads. Safety Safety Labels and Locations Operation Warning WARNING Improper ATV use can occur with another vehicle; a collision can result in turns;
... skills or the conditions; Never use an approved helmet and protective gear. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376 + 33 avoid paved surfaces - Never carry passengers. pavement may seriously affect handling and control. LOCATE AND READ OWNER'S MANUAL. Always use on public roads - on public roads. Safety Safety Labels and Locations Operation Warning WARNING Improper ATV use can occur with another vehicle; a collision can result in turns;
Owners Manual
Page 48
... ignition switch key must always be turned on before pushing the starter button. If you drive. Ignition Switch 10. Ignition Switch 9. Be careful not to your ATV. Tether Strap and Switch - Tether Switch OUTLAW SPORTSMAN Never ride without the tether strap attached to your right wrist and to let the cord get tangled around the handlebars or any part of your ATV every time...
... ignition switch key must always be turned on before pushing the starter button. If you drive. Ignition Switch 10. Ignition Switch 9. Be careful not to your ATV. Tether Strap and Switch - Tether Switch OUTLAW SPORTSMAN Never ride without the tether strap attached to your right wrist and to let the cord get tangled around the handlebars or any part of your ATV every time...
Owners Manual
Page 61
... the engine stop switch down , in case of stuck throttle or other emergency. Horn Stop Switch Start Button Choke Lever Choke Lever Use the choke to the left before starting the engine. Push the choke lever to start or run when the stop switch is to the OFF position as the engine warms up and runs smoothly. 58 Features and Controls Engine Stop Switch The engine will not start a cold engine.
... the engine stop switch down , in case of stuck throttle or other emergency. Horn Stop Switch Start Button Choke Lever Choke Lever Use the choke to the left before starting the engine. Push the choke lever to start or run when the stop switch is to the OFF position as the engine warms up and runs smoothly. 58 Features and Controls Engine Stop Switch The engine will not start a cold engine.
Owners Manual
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Refer to the specifications section beginning on page 162 for fuel tank capacity. Gas Cap 66 Use unleaded gasoline with ethanol content greater than 10 percent, such as E-85 fuel. Features and Controls Fuel System 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.
Refer to the specifications section beginning on page 162 for fuel tank capacity. Gas Cap 66 Use unleaded gasoline with ethanol content greater than 10 percent, such as E-85 fuel. Features and Controls Fuel System 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.
Owners Manual
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SPORTSMAN 90 Fuel Valve The reserve setting allows operation for approximately 7-10 miles (11-16 km). OFF OUTLAW 90 Fuel Valve ON RES 67 ON: For normal operation. Always return the valve to the ON position after using the main supply. OFF: For vehicle storage and when transporting. 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. It has three settings. Features and Controls Fuel Valve The fuel valve is exhausted.
SPORTSMAN 90 Fuel Valve The reserve setting allows operation for approximately 7-10 miles (11-16 km). OFF OUTLAW 90 Fuel Valve ON RES 67 ON: For normal operation. Always return the valve to the ON position after using the main supply. OFF: For vehicle storage and when transporting. 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. It has three settings. Features and Controls Fuel Valve The fuel valve is exhausted.
Owners Manual
Page 71
... ATV. Lock the parking brake. 4. Store the lever under the seat when it's not installed. 5. Place your heel downward to crank the engine. 8. Push the engine stop switch up to ON. Fold out the kick-start lever on the kick-start shaft to protect the rider. Tip: A 10/12mm wrench is serviced. 1. Shift the transmission to neutral. 3. Features and Controls Kick-Start Lever If the battery becomes...
... ATV. Lock the parking brake. 4. Store the lever under the seat when it's not installed. 5. Place your heel downward to crank the engine. 8. Push the engine stop switch up to ON. Fold out the kick-start lever on the kick-start shaft to protect the rider. Tip: A 10/12mm wrench is serviced. 1. Shift the transmission to neutral. 3. Features and Controls Kick-Start Lever If the battery becomes...
Owners Manual
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Lock the parking brake. 6. Stop the engine. There are three ways to neutral. Shift the transmission to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. 5. Apply the brakes until the vehicle stops moving. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. 78 Release the throttle completely. Operation Stopping the Engine 1. 2. 3. 4.
Lock the parking brake. 6. Stop the engine. There are three ways to neutral. Shift the transmission to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. 5. Apply the brakes until the vehicle stops moving. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. 78 Release the throttle completely. Operation Stopping the Engine 1. 2. 3. 4.
Owners Manual
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Emission Control Systems Exhaust Emission Control System The emissions from the exhaust 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. The installation of devices that the operator perform. Engine idle speed is located on the clutch cover or engine case near the clutch box. Electromagnetic Interference This spark ignition system complies with the EMC...
Emission Control Systems Exhaust Emission Control System The emissions from the exhaust 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. The installation of devices that the operator perform. Engine idle speed is located on the clutch cover or engine case near the clutch box. Electromagnetic Interference This spark ignition system complies with the EMC...
Owners Manual
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E Emission-Related Service Q Have an authorized Polaris dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; Maintenance Periodic Maintenance Chart Item E Q XQ QE QE X Q Carburetor air intake ducts/flange Drive belt Brake pad wear Fuel system Fuel filter Engine mounts Exhaust muffler/pipe Ignition timing Maintenance Interval (whichever comes first) Hours 50 50 50 100 100 100 100 100 Calendar 6M 6M 6M 12 M 12 M 12 M 12 M 12 M Miles (Km) 500 (800...
E Emission-Related Service Q Have an authorized Polaris dealer perform these procedures more often for leaks at tank cap, lines, fuel valve, filter, pump, carburetor; Maintenance Periodic Maintenance Chart Item E Q XQ QE QE X Q Carburetor air intake ducts/flange Drive belt Brake pad wear Fuel system Fuel filter Engine mounts Exhaust muffler/pipe Ignition timing Maintenance Interval (whichever comes first) Hours 50 50 50 100 100 100 100 100 Calendar 6M 6M 6M 12 M 12 M 12 M 12 M 12 M Miles (Km) 500 (800...
Owners Manual
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Maintenance Periodic Maintenance Chart Item Wiring Clutches (drive and driven) Front wheel bearings Spark arrestor Q Toe adjustment Maintenance Interval (whichever comes first) Hours Calendar 12 M 12 M 12 M 36 M -Miles (Km) 1000 (1600) 1000 (1600) 1000 (1600) 3000 (4800) 100 100 100 300 Remarks Inspect for wear, routing, security; replace worn parts Inspect; Inspect; clean; adjust when parts are replaced See Page ---122 134 X Q Q 105 replace as needed Clean out Inspect periodically; apply dielectric grease to connectors subjected to water, mud, etc.
Maintenance Periodic Maintenance Chart Item Wiring Clutches (drive and driven) Front wheel bearings Spark arrestor Q Toe adjustment Maintenance Interval (whichever comes first) Hours Calendar 12 M 12 M 12 M 36 M -Miles (Km) 1000 (1600) 1000 (1600) 1000 (1600) 3000 (4800) 100 100 100 300 Remarks Inspect for wear, routing, security; replace worn parts Inspect; Inspect; clean; adjust when parts are replaced See Page ---122 134 X Q Q 105 replace as needed Clean out Inspect periodically; apply dielectric grease to connectors subjected to water, mud, etc.
Owners Manual
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... recommended oil. Under These Operating Conditions Outside air temperature is above 32° F/0° C Outside air temperature is not used. Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98. See page 166 for the part numbers of Polaris products. Oil may need to be changed more frequently if Polaris oil is...
... recommended oil. Under These Operating Conditions Outside air temperature is above 32° F/0° C Outside air temperature is not used. Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98. See page 166 for the part numbers of Polaris products. Oil may need to be changed more frequently if Polaris oil is...
Owners Manual
Page 128
Lock the parking brake. 3. Turning the screw in or out until the desired idle RPM is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine. 2. Allow the engine to run for approximately five minutes. 4. Turning the screw out (counterclockwise) will raise RPM. Adjust the carburetor idle screw either in (clockwise) will lower RPM. 125 Maintenance Carburetor If the engine idle speed is reached.
Lock the parking brake. 3. Turning the screw in or out until the desired idle RPM is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine. 2. Allow the engine to run for approximately five minutes. 4. Turning the screw out (counterclockwise) will raise RPM. Adjust the carburetor idle screw either in (clockwise) will lower RPM. 125 Maintenance Carburetor If the engine idle speed is reached.
Owners Manual
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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
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... you specific legal rights, and you use your dealer to resolve any Polaris Servicing Dealer to perform warranty service. Spark Arrestor Polaris warrants that you may use of Polaris engine oil. 2. When requesting warranty service you must present your ATV requires warranty service, you may also have other warranty terms will remain in accordance with your original selling dealer; Damage resulting from the use and when maintenance...
... you specific legal rights, and you use your dealer to resolve any Polaris Servicing Dealer to perform warranty service. Spark Arrestor Polaris warrants that you may use of Polaris engine oil. 2. When requesting warranty service you must present your ATV requires warranty service, you may also have other warranty terms will remain in accordance with your original selling dealer; Damage resulting from the use and when maintenance...
Owners Manual
Page 186
... DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. You should take your vehicle was purchased, you should consult an authorized dealer to Get Service In the country where your vehicle to Safety Recalls. Upon residence verification, the servicing dealer will be done by an authorized Polaris dealer. This policy does not apply to an authorized...
... DEALER'S AUTHORIZED LOCATION. This policy does not apply to perform the warranty repair. You should take your vehicle was purchased, you should consult an authorized dealer to Get Service In the country where your vehicle to Safety Recalls. Upon residence verification, the servicing dealer will be done by an authorized Polaris dealer. This policy does not apply to an authorized...
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 197
... Oil Change, Engine ...110-112 Oil Change, Transmission ...115 Oil Check, Engine ...109 Oil Check, Transmission ...114 Oil, Engine ...108 Operator Restrictions ...13 L Parking on a Hill or Incline ...90 Periodic Maintenance Chart . . 98-105 Polaris Products ...166 Polishing ...156 Pre-Ride Inspection ...72-73 Restrictions, Age...13 Riding Gear ...10-11 Safe Operation Practices ...74-75 Safety Labels Age Warning ...32 Clutch Cover Warning ...38 Discretionary Warning ...34 No Passenger Warning ...36 Operation Warning ...33 Passenger Warning ...36 Rack Warning...
... Oil Change, Engine ...110-112 Oil Change, Transmission ...115 Oil Check, Engine ...109 Oil Check, Transmission ...114 Oil, Engine ...108 Operator Restrictions ...13 L Parking on a Hill or Incline ...90 Periodic Maintenance Chart . . 98-105 Polaris Products ...166 Polishing ...156 Pre-Ride Inspection ...72-73 Restrictions, Age...13 Riding Gear ...10-11 Safe Operation Practices ...74-75 Safety Labels Age Warning ...32 Clutch Cover Warning ...38 Discretionary Warning ...34 No Passenger Warning ...36 Operation Warning ...33 Passenger Warning ...36 Rack Warning...
Owners Manual
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... ...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 Arrestor ...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 Arrestor ...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...