WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
We’ve created a web site just for YOU! S S S S S S Technical tips Accessories and apparel New product introductions Event schedules Parts and Service Manual information Exciting details about The Way Out Check it out... www.polarisindustries.
Copyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies.
Welcome Dear Parents: We believe your children should have the opportunity to enjoy The Way Out experience along with you. We’ve provided this owner’s manual to assist you and your children in learning about safe operation and care of your new ATV. Please review the information in this manual with any child who may operate the ATV. Help your children learn to operate the ATV with safety as a top priority.
Welcome Dear Children: Before you ride your new Polaris ATV, there are some important things that you need to know. Your parents and Polaris want you to enjoy riding your new ATV, and that’s why you need to read and understand the information in your owner’s manual. Ask your parents to explain anything you don’t understand, and pay close attention to the warnings and instructions you read. Your safety and the safety of others is the most important thing to think about at all times.
Welcome . . . . . . . . . . . . . . . . . 3 Safety . . . . . . . . . . . . . . . . . . . . 7 Youth Section . . . . . . . . . . . . 17 Know Your ATV . . . . . . . . 18 Pre-Ride Check . . . . . . . . 25 Riding Rules . . . . . . . . . . . 28 Table of Contents Adult Section . . . . . . . . . . . . 33 Safety Decals . . . . . . . . . . 34 Driver Warnings . . . . . . . . 47 Vehicle ID Numbers . . . . 70 Features and Controls . . 71 Break-in Period . . . . . . . . 88 Pre-Ride Inspections . . .
6
Safety Understand the Warnings Always follow the age guidelines for your ATV. Never allow a younger child to ride on or drive the ATV. Make sure all operators understand all warnings and the owner’s manual before driving the ATV. Know Your ATV Before Riding Parents must help their children learn the proper and safe way to ride an ATV. Read the owner’s manual with your children before starting the engine for the first time, and review it with them periodically afterwards.
Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for personal injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
Safety WARNING Failure to follow the warnings in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand the owner’s manual and all warnings before operating a Polaris ATV.
Safety S Read this manual and all labels carefully and follow the operating procedures described. S 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.
S 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. S Never consume alcohol or drugs before or while operating this ATV. S Never operate at excessive speeds. Always travel at a speed which is proper for the terrain, visibility and operating conditions, and your experience. S Never attempt wheelies, jumps or other stunts.
Safety S 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 excessive speed. S Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident. S Never operate the ATV on hills too steep for the ATV or for your abilities. Practice on smaller hills before attempting larger hills.
S 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. Safety S Always use proper procedures if you stall or roll backwards when climbing a hill.
Safety S Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. S Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (pg.
Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
16
Youth Section 17
Know Your ATV PARENTS: Polaris Youth ATVs are equipped with an electronic speed control system to allow adults to limit the speed of the vehicle for the rider’s skill and experience. More information on speed limiting functions can be found beginning on page 135. These units are not designed for adult use. Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded. See the specifications section beginning on page 162 for your ATV’s capacity.
Know Your ATV Before you have an adult start the engine for you for the first time, let’s learn about the controls on your new ATV. 1. Engine Stop Switch - When the engine is running, push this button down to shut the engine off quickly. The button must be up before you can start the engine again. 2. Horn Button (90 cc models) - Press the horn button to sound the horn. 3. Throttle Control - Press the throttle lever with your thumb when you want the ATV to go forward.
Know Your ATV 4. Kick-Start Lever - If your battery is too weak to start your ATV, you can push down on the kick-start lever with your foot to start the engine. Have an adult show you how it works. Read more about how to use the kick-start on page 86. 5. Shift Lever (90cc models) - The shift lever is on the right side of your ATV. Read about how to use the shift lever on page 76.
Know Your ATV 6. Gas Cap - The gas cap has to be taken off when an adult puts gas in your ATV. Never take the gas cap off. Always make sure it’s tightly closed. 6 7 Always have an adult put gas in your ATV. Never try to do it yourself. 7. Seat Latch - To remove the seat, pull up on the seat latch on the lefthand side of the seat. To replace the seat, set it in place and push down on the seat above the latch. Always make sure the seat is locked in place before riding.
Know Your ATV 8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The lefthand lever (8A) controls the rear brake. The righthand lever (8B) controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured. Always take your thumb off the throttle lever when you squeeze the brake levers.
Know Your ATV 9. Ignition Switch - The ignition switch key must be turned on before pushing the starter button. You can also use this key to turn off the engine. 10. Tether Strap and Switch - The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive. If you fall off your ATV, the tether strap will pull away from the switch and the engine will stop. 10 9 10 9 Never ride without the tether strap attached to your right wrist and to your ATV.
Know Your ATV Let’s review the three ways to stop your ATV: 1. Push the stop switch down. 2. Pull off the tether strap. 3. Turn the key off.
Pre-Ride Check We’re almost ready to have an adult start your ATV. But before the ATV is started for the first time, you must do a Pre-Ride Check. In fact, every time you want to ride you must have an adult help you check some things on your ATV before starting it. Let’s learn about these things now. Make sure the throttle doesn’t stick. Check this by pushing the throttle lever toward the handlebar and then letting go. The lever should come right back to where it was before you pushed it.
Pre-Ride Check Make sure the brakes don’t stick. Check the brake levers by squeezing them toward the handlebar and then letting go. They should come right back to where they were before you squeezed. If they go back slowly or stay close to the handlebar, your ATV has sticky brakes. They must be fixed before you can ride your ATV safely. Never start the engine if your ATV has sticky brakes. You could be seriously hurt if you ride with sticky brakes.
Pre-Ride Check If you used the storage area under the seat, make sure the seat is locked in place. Have an adult check the engine oil level when the engine is cold. The engine is very hot after it has been running and it can burn your skin if you touch it. Children must never check the oil on their own. An adult should always be in charge of keeping the gas and oil levels at the full marks. This last check is done with the engine running.
Riding Rules Now you’re ready to learn about riding your Polaris ATV. There are some things you can do and there are some things you must never do. Rules are very important when you’re driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride. The adult with you is your teacher. Always pay attention to what your teacher says so you can learn how to always drive safely. Let’s learn how to ride! Always follow the safe riding rules found on the next pages.
Riding Rules " Always wear the right kind of clothing and safety gear when riding your ATV. 1. Helmet: Your helmet is very important for safe riding. A helmet can prevent a severe head injury. 2. Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep them clean so you can 1 see where you’re driving. 3. Gloves: Wear gloves to protect your hands from sun and wind. Gloves will also protect your hands from scrapes and scratches. 2 4.
Riding Rules " " " " " " Always attach the tether strap to your right wrist and to the ATV before riding. Make sure you know where you’re going to drive before your ATV is started. Make sure the area is safe all around your ATV. Your ATV is made for one person. Never carry a passenger. A passenger will make the ATV harder to drive. You you may lose control and hurt yourself and your passenger. Always drive your ATV while sitting down.
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. Don’t ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or trains that may be coming towards you. Don’t ride at night. Your ATV doesn’t have lights that are safe for driving in the dark.
Respect your ATV; respect your environment; and you will earn the respect of everyone.
Adult Section 33
Safety Decals Warning and safety decals have been placed on the ATV for the protection of the operator. Read and follow the instructions on each decal carefully. If any safety decal becomes illegible or comes off, contact your Polaris dealer for a free replacement. The part number is printed on the decal.
Safety Decals 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.
Safety Decals Predator 50 Age Warning Decal L 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 Owner’s 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.
Safety Decals Predator 50 Age Warning Decal 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 Owner’s Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. 15°. To prevent flipover on S Never operate this ATV on HILLS steeper than 15 degrees hilly terrain, use throttle and brakes gradually.
Safety Decals Predator 90/Sportsman 90 Age Warning Decal L 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 Owner’s 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°.
Safety Decals Predator 90/Sportsman 90 Age Warning Decal 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 Owner’s Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. 15°.
Safety Decals 1 2 1 1 WARNING 7172566 40 2
Safety Decals 2 (Predator 50) WARNING 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 311 LBS. 7172684 2 (Predator 90) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 3 (20.7) REAR 3 (20.
Safety Decals 4 3 42
Safety Decals ATTENTION 3 S Operation of this vehicle without the filter element will severely damage the engine. S Clean air filter often, more frequent cleaning required in dusty conditions. S Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory Setting: 40° to 80° F. at 0-3000 feet. (5° to 27° C.
Safety Decals 6 5 44 6 5
Safety Decals WARNING 5 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. 7172679 WARNING MANUFACTURED IN TAIWAN DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 10 lbs.
46
Driver Warnings Be sure to read all of the following warnings about driving hazards and how to avoid them. These warnings are provided for your child’s safety, so be sure to explain to your young driver that the following hazards MUST be avoided at all times.
Driver Warnings WARNING 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.
Driver Warnings WARNING 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 she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious accident.
Driver Warnings WARNING 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 operation. It is not for passengers.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, 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 the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever possible. If you must ride on a paved surface, go slowly and do not make sudden turns or stops.
Driver Warnings WARNING 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.
Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective 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 accident 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.
Driver Warnings WARNING 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.
Driver Warnings WARNING WARNING 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 accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating conditions; and your experience. 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.
Driver Warnings WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving (don’t show off).
Driver Warnings WARNING 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.
Driver Warnings WARNING 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.
Driver Warnings WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you’ve learned and practiced the skills necessary to control the ATV on such terrain.
Driver Warnings WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speed.
Driver Warnings WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner’s Manual beginning on page 100. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight forward. Never open the throttle suddenly. The ATV could flip over backwards.
Driver Warnings WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Driving downhill improperly could cause loss of control or ATV overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 106. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill. Shift your weight backward. Never go down a hill at high speed.
Driver Warnings WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never try to turn the ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 104. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill.
Driver Warnings WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The ATV could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep your weight uphill. Apply the front brakes gradually (right lever). When fully stopped, apply the rear brake as well (left lever) and then lock the parking brake. If you begin rolling backwards: Keep weight uphill. Never apply engine power.
Driver Warnings WARNING WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control. POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn.
Driver Warnings 66 WARNING WARNING 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. POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident.
Driver Warnings WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
Driver Warnings 68 WARNING WARNING POTENTIAL HAZARD Overloading the ATV. WHAT CAN HAPPEN Overloading the ATV could cause changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. If equipped with racks, cargo should be properly distributed and securely attached. POTENTIAL HAZARD Operating the ATV with improper modifications.
Driver Warnings WARNING WARNING 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. Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.
Vehicle Identification Numbers Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. The Predator 50 VIN is located on the righthand lower frame tube. The Predator 90 and Sportsman 90 VIN is located on the righthand front upper shock mount.
Features and Controls Main Switch (A) The main switch is located on the pod. This switch is operated with a key and must be turned clockwise to the ON position before starting the engine. WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.
Features and Controls Engine Stop Switch (B) The stop switch (B) is located on the top of the left handlebar. The engine will not start or run when the stop switch is down, in the 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 quickly, push the stop switch down.
Features and Controls Engine Start Button (E) The start button is located slightly above the choke lever. To start the engine, make sure the tether strap is securely plugged into the machine and attached to the rider’s right wrist. If you have a 90cc model, make sure the shift lever is in neutral. The neutral light will come on when the lever is in neutral. See page 81. 1. Turn the key to the ON position. 2. Set the parking brake. 3. Push the start button up to the ON position. 4. Press the start button.
Features and Controls Throttle Controls WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
Features and Controls Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever (A). The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with an Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop and power to the rear wheels will cease.
Features and Controls Shift Lever (90cc models) To change gears, stop the ATV. With the engine idling, move the lever (1) to the desired gear. Do not try to shift gears with engine speed above idle or while the ATV is moving. Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.
Features and Controls CAUTION Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle. Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended.
Features and Controls Brakes To activate the rear brake, squeeze the lefthand lever (A) toward the handlebar. The front brakes are activated by squeezing the lever (B) on the righthand handlebar. WARNING Applying only one brake could cause loss of control and result in serious injury or death. Always apply both brakes at the same time.
Features and Controls Brakes Setting the Parking Brake 1. Squeeze the lefthand brake lever (A). 2. Push the park brake lock (B) down. This will prevent the lever from returning to the released position. 3. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. A B B WARNING Operating the ATV while the parking brake is engaged could cause an accident resulting in serious injury or death. It could also result in driveline or engine damage.
Features and Controls Brakes Parking Brake NOTE: The Predator 50 has a PVT system that’s always in forward. Always lock the park brake before starting the engine. Since the transmission is always in forward gear, activating the throttle to warm the engine will make the machine move forward if the park brake is not locked. On 90cc models, always shift the transmission to neutral and lock the park brake before starting the engine.
Features and Controls Lights WARNING Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visibility. This ATV is designed for off-road use only. Do not operate this ATV on streets or highways. Indicator Lights Indicator lights on the ATV let you know when your ATV is in neutral or reverse (90cc models). The low oil light comes on if the engine oil level gets too low.
Features and Controls Oil System CAUTION Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris VES II Synthetic 2-cycle oil or Polaris Premium Gold Synthetic 2-cycle oil. Never substitute or mix oil brands. To avoid serious engine damage, always top off the oil level when refueling. The oil tank (A) is located under the seat and has a capacity of 1.1 quarts (1 liter). Always top off the oil level when refueling.
Features and Controls Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Do not fill the tank neck.
Features and Controls Fuel System WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas. Gas Cap The fuel tank filler cap (A) is located directly below the handlebars. The tank has a capacity of 1.3 gallons (5 liters). Use unleaded gasoline with a minimum pump octane of 87.
Features and Controls Fuel System Fuel Valve RES The fuel valve is located on the lefthand side of the ATV. It has three positions: OFF: For vehicle storage and when OFF transporting. ON: For normal operation. ON RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 7-10 mile (11-16 km) Sportsman range on reserve gas. Always refill the gas tank as soon as possible after using the main supply. Always return the valve to the ON position after refueling.
Features and Controls Kick-Start Lever A If the battery becomes too weak to start the engine, the kick-start lever will allow you to start the engine until the battery is serviced. Be sure the ATV is on a level surface with the parking brake locked. Make sure the transmission is in neutral (90cc models). 1. Fold out the kick-start lever (A) on the lefthand side of the ATV. 2. Make sure the stop switch is in the RUN position and turn the key to ON. 3.
Features and Controls Footwell Riser The removeable footwell risers on the Predator 50 improve riding ergonomics and provide comfort for shorter operators. An operator will also have better control of the ATV when both feet can remain firmly planted on either the footwells or the risers. If the operator’s legs are long enough to comfortably reach the footwells without the risers, the risers can be removed. 1. Remove the rubber caps (A) covering the screw access holes. 2.
Break-in Period The break in period for your new Polaris ATV is the length of time it takes to use the first tank of gas. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. CAUTION Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts.
Break-in Period 2. Fill the oil tank with Polaris-recommended oil. NOTE: Always be sure to top off the oil level whenever refueling. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection. See page 90. 6.
Daily Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the ATV before each use to ensure it’s in proper operating condition. Use the following checklist to make sure the ATV is in proper working condition before each use. 1. 2. 3. 4. 5. 6. 7. 8. 90 Tires - Check condition and pressures. Fuel and oil tanks - Fill both tanks. All brakes - Check operation/adjustment. Throttle - Check for free operation and proper closing.
Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. Shift the transmission to neutral (90cc models). 2. Set the parking brake and turn the fuel tank valve to ON. 3.
Starting the Engine 4. If the engine is cold, use full choke by pushing the choke lever all the way to the left. A warm engine will not require the use of the choke. 5. Turn the engine stop switch to RUN, then turn the ignition key to ON. NOTE: Do not press the throttle while starting the engine. 6. Squeeze the rear brake lever and press the starter button. NOTE: The rear brake lever must be engaged or the engine won’t start. 7.
Stopping the Engine 1. Release the throttle completely and brake to a complete stop. 2. Put the shift lever into neutral (90cc models). 3. Lock the parking brake. WARNING A rolling vehicle can cause property damage and serious injury. Always apply the parking brake after stopping the engine.
Driving Safely Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury. Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.
Driving Safely 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet 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 boots with heels, like moto-cross boots. 5.
Driving Safely Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Place the transmission in neutral (90cc models). 3. Start the engine and allow it to warm up. 4. Check your surroundings and determine your path of travel. 5. Squeeze the brake levers. 6. Shift the transmission to the desired gear (90cc models). 7. Release the parking brake and slowly release the brake levers. 8. Slowly depress the throttle with your right thumb and begin driving. 9.
Driving Safely Making Turns Your ATV is 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 footrest.
Driving Safely Driving on Slippery Surfaces WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control, accident, and serious injury or death. Never apply the brakes during a skid. Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution.
Driving Safely Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 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.
Driving Safely Driving Uphill WARNING Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (15_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual.
Driving Safely Whenever traveling uphill, follow these precautions: 1. 2. 3. 4. 5. Always travel straight uphill. Avoid steep hills (15_ maximum). Keep both feet on the footrests. Transfer your weight forward. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
Driving Safely Driving Across Hillsides WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual.
Driving Safely Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper body weight uphill while keeping your feet on the footrests. 3. Steer slightly into the hill to maintain direction.
Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death. Avoid climbing steep hills (15_ maximum). Use extreme caution when operating on hills, and follow proper operating procedures outlined in the owner’s manual. If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn: 1. 2. 3. 4.
Driving Safely 5. Staying uphill of the ATV, turn the handlebars full left. 6. While holding the brake, release the parking brake lock and slowly release the brake, allowing the ATV to roll around to your right until it’s pointing across the hill or slightly downward. 7. Lock the parking brake and remount the ATV from the uphill side, maintaining body weight uphill. 8. Restart the engine. 9. Squeeze the rear brake lever. 8’ 10. Shift the transmission to forward gear (90cc models). Uphill 11.
Driving Safely Driving Downhill Whenever descending a hill, follow these precautions: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the front and rear brakes at the same time, and very slightly, to aid in slowing. WARNING Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.
Driving Safely Parking on a Hill or Incline Avoid parking on a hill or incline if possible. If it’s unavoidable, follow these precautions: 1. Turn the engine off. 2. Set the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illustration. 4. Shut off the fuel supply.
Driving Safely Driving Through Water Your ATV can safely operate through shallow water. The recommended maximum depth for your ATV is below the bottom of the footrests (A). Follow these procedures when operating through water: 1. Determine water depths before driving through water. 2. If crossing a stream, choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and A obstacles if possible. 4.
Driving Safely Avoid operating your ATV through deep or fast flowing water. If the ATV is operated in deeper water than recommended, it’s critical to have it serviced as outlined in the maintenance chart beginning on page 122. The following areas need special attention: engine oil, gearcase oil, front and rear gearcases and all grease fittings. CAUTION Major engine damage can result from driving this ATV in deeper water than recommended.
Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all obstacles are immediately visible. Travel with caution in unfamiliar terrain.
Driving Safely Driving in Reverse (90cc models) Follow these guidelines when operating in reverse: 1. Back slowly. 2. Apply the brakes lightly for stopping. 3. Avoid turning at sharp angles. 4. Always avoid backing downhill. 5. Never open the throttle suddenly while backing. 6. Always look left, right and behind the ATV before backing. WARNING Failure to use caution when operating in reverse can result in serious injury or death.
Hauling Cargo The Sportsman 90 was designed to carry a certain amount of load. Never exceed the weight capacities listed in the specifications section of the owner’s manual. Never carry cargo on a Scrambler. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
Hauling Cargo 2/3 of Load on Rear Rack 1/3 of Load on Front Rack S REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. S 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. S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS.
Hauling Cargo S ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE. Unse- S S S S cured loads can create unstable operating conditions, which could result in loss of control of the vehicle. LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle 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.
Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris ATV is not equipped with a spark arrestor approved by the USDA Forest Service. Operating this ATV on U.S. public lands without a spark arrestor is in violation of federal law.
Maintenance PVT System WARNING 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 following responsibilities to make sure this system remains safe: 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.
Maintenance PVT System If the ATV is operated in dusty areas, clean the PVT filter more often than recommended for normal conditions. To clean the PVT filter: 1. 2. 3. 4. Remove the screws and the crankcase cover. Remove the screws and the filter cover. Soak the filter in a mild detergent and rinse with clean water. Allow the filter to air dry, then reinstall. CAUTION Exposure to salt water will cause corrosion to metal components.
Maintenance Battery The battery in your Polaris ATV is a sealed battery. The sealing strip cannot be removed. Never add water to this type of battery. Keep the battery terminals and connections 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 shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Maintenance Battery Battery Removal 1. 2. 3. 4. Disconnect the hold-down straps securing the electrical box and battery in position. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable next. Lift the battery out of the ATV.
Maintenance Battery Battery Installation and Connections 1. Set the battery in its holder. 2. Connect and tighten the red (positive) cable first. 3. Connect and tighten the black (negative) cable last. 4. Attach the hold-down strap. 5. Verify that cables are properly routed. NOTE: When installing a new battery, make sure it’s fully charged prior to its initial use. Using a new battery that has not been fully charged can damage the battery and result in a shorter life.
Maintenance Periodic Maintenance Schedule To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kit are: S Spark plug wrench S Screwdriver S Tire pressure gauge 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.
Maintenance Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.
Maintenance Periodic Maintenance Schedule Item to Inspect Frequency Remarks Brake System Hours/ Miles Pre-ride Pre-ride Inspect Tires Pre-ride Pre-ride Inspect Wheels Pre-ride Pre-ride Inspect Frame nuts, bolts, fasteners Throttle Pre-ride Pre-ride Inspect; tighten any loose hardware Pre-ride Pre-ride Check for proper operation Engine stop switch Pre-ride Pre-ride Check for proper operation Engine oil Pre-ride Pre-ride Check level; fill oil when refueling " Air Filter Pre-ride
Maintenance Periodic Maintenance Schedule Item to Inspect Hours/ Miles 50 hrs Frequency Remarks 6 months Carburetor Float Bowl J Throttle Cable/ETC Switch " Steering 50 hrs 6 months 50 hrs 6 months 50 hrs 6 months Inspect; adjust; lubricate; replace if required Drain bowl periodically and prior to storage Inspect; adjust; lubricate; replace if necessary Inspect; lubricate " Rear Axle 50 hrs 6 months Inspect bearings; lubricate " Drive Chain 50 hrs 6 months Inspect; adjust and lubricate i
Maintenance Periodic Maintenance Schedule Item to Inspect Frequency Remarks Spark Plug Hours/ Miles 100 hrs 12 months Inspect; replace if necessary J Ignition Timing 100 hrs 12 months Inspect; adjust as needed J Fuel System 100 hrs 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years.
Maintenance Lubrication Recommendations Item 1. Engine Oil Lube Method Polaris VES II Synthetic 2-cycle AGL Synthetic gearcase lube Fill oil tank. 3. Drive Chain Polaris chain lube or SAE 80/90 4. Front A-Arm " Lubricate as required and before each ride in wet conditions. Locate fittings and grease. 2. Gearcase Oil Level L Grease See Page 146. Frequency As needed and when refueling Change annually or at 100 hrs. Maintain in SAFE range. As required Every 3 months or 50 hrs.
Maintenance Lubrication Recommendations 4 2 4 90cc Models 50cc Models 127
Maintenance Lubrication Recommendations Polaris 2-Cycle Lubricants Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. These oils provide additives for 2-cycle engines that are lacking in today’s fuel. These additives keep ring grooves cleaner for less ring sticking and improved overall engine cleanliness. We recommend the use of these oils for all Polaris 2-cycle engines.
Maintenance Lubrication Recommendations Polaris VES II Synthetic 2-Cycle Oil Your ATV has been primed with VES II synthetic oil. We recommend the continued use of this oil. It’s been formulated for low smoke, low odor, low deposits and high lubricity. Premium 2-Cycle Oil Polaris Premium Gold Synthetic 2-Cycle Oil is also suitable for use.
Maintenance Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed First 5 hrs. 25 hrs. 50 hrs. 75 hrs. 100 hrs.
Maintenance Periodic Maintenance Record Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 131
Maintenance Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster (A) in the direction required to increase or decrease spring tension. A Handlebar Adjustment WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and possible serious personal injury or death.
Maintenance Handlebar Adjustment The handlebars can be adjusted for rider preference. 1. Remove the pod to access the handlebar bolts. 2. Loosen the four bolts (A). 3. Adjust the handlebar to the desired height. Be sure the handlebars do not hit the gas tank or any other part of the machine when turned fully to the left or right. 4. Lightly tighten each bolt equally to prevent uneven gaps in the block. 5. Torque the handlebar adjuster block bolts to 7.3 ft. lbs. (10 Nm).
Maintenance Axle and Wheel Nut Torque Specifications Check the following nuts occasionally and when they’ve been loosened for maintenance. Specification Front Spindle Nuts 42-45 ft. lbs. (57-61 Nm) Rear Spindle Nuts 78-81 ft. lbs. (106-110 Nm) NOTE: All nuts with a cotter pin installed must be serviced by an authorized Polaris dealer. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations.
Maintenance Speed Control Systems Per ANSI / SVIA--1--2001 (sec. 6.1.3) AS DELIVERED TO THE CONSUMER, the speed of youth models is restricted to under 10 MPH for the 50 cc models and under 15 MPH for the 90 cc models. The dealer CANNOT, under any circumstances, either prior to the sale or later, even at the consumer’s request, remove or adjust any speed limiting devices. Polaris Youth ATVs have an electronic speed control system and an adjustable throttle limiting screw.
Maintenance Speed Control Systems A A Electronic Speed Control System Your Polaris ATV has a speed control system that controls engine RPM and speed of the ATV. Adjust speed by removing or installing the jumper on the CDI (A). With the jumper installed, 50cc models will travel no faster than 10 mph and 90cc models will travel no faster than 15 mph. With the jumper removed, 50cc models will travel no faster than 15 mph and 90cc models will travel no faster than 30 mph.
Maintenance Speed Control Systems Throttle Stop Speed Control System Adjusting speed at the CDI is the recommended method of speed control, but the throttle stop system may also be used. Use the following procedure to control how far the throttle opens. A B 1. Loosen the jam nut (A) 2. Turn the screw (B) inward to reduce speed or outward to increase speed. 3. Tighten the jam nut after adjusting.
Maintenance Steering Inspection The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe alignment of the vehicle.
Maintenance Toe Alignment 3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle (B). 4. Measure the distance from the string to the rim at the front and rear of the front rim (C). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service.
Maintenance Throttle Cable Adjustment Always check the throttle for smooth operation before riding. Periodically check the throttle freeplay. It should be kept between 1/16″ and 1/8 ″ (1.5mm - 3.2mm) (A). If adjustment is required, turn the adjustment nut (B) until the freeplay falls in to the acceptable limit. B A Brake Freeplay Brake Freeplay Specifications Model Front Rear Predator 50 .1″ - .39 ″ (2.5-9.9 mm) .15″ - .30″ (3.8-7.6 mm) Predator 90 .40″ - .80″ (10-20 mm) .40″ - .
Maintenance Brake Adjustment A Periodically check (measure) the freeplay of the front and rear brakes (A). Refer to the specifications chart on page 140 for the acceptable range of freeplay. To adjust the front brake freeplay, turn the adjustment knob (B). To adjust the rear brake freeplay, turn the adjuster nut (C). B Brake Lever Travel Service the brakes when brake lever travel (D) reaches the following total lever travel measurements.
Maintenance Air Cleaner B Inspect the air filter weekly or after every 50 hours of operation. If the ATV is ridden in wet or dusty conditions, clean the filter more often. 1. Remove the screws (A) on the airbox and remove 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. A CAUTION Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage to the engine.
Maintenance Carburetor Adjustments Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for each 1000-foot (304.8 m) increase in elevation.
Maintenance Spark Plugs S Use NGK BP7HS or NGK BPR7HS spark plugs. S Proper electrode gap is .24”-.28” (0.6-0.7 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. CAUTION Using non-recommended spark plugs can result in serious engine damage.
Maintenance Spark Plugs NORMAL: The normal 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. WET FOULED: The wet fouled insulator tip is black. A damp oil film covers the firing end.
Maintenance Cylinder Head/Cylinder Base Fastener Torque Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Gearcase Lubrication The gearcase fill plug (A) is located on the top of the gearcase. The sight glass (B) is on the righthand side of the gearcase. The oil level must be maintained in the safe zone of the sight glass. It should be checked monthly and changed annually.
Maintenance Gearcase Oil Change 1. 2. 3. 4. Remove the fill plug. Remove the gearcase drain plug and drain the oil into a drain pan. Dispose of properly. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). Add AGL Synthetic Gearcase Lubricant to the safe zone in the sight glass. Model Total Capacity Capacity at Oil Change 50cc Models 10 oz. (300 ml) 7 oz. (200 ml) 90cc Models 20.25 oz. (600 ml) 16.25 oz. (480 ml) 5. Replace the fill plug and check for leaks.
Maintenance WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual. Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (.3 cm) or less.
Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration. 1/8I (.3 cm) Wheel Removal 1. Stop the engine 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.
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. Install the wheel bolts (A) and finger tighten them. 3. Lower the vehicle to the ground. 4. Securely tighten the bolts to 22 ft. lbs. (30 Nm).
Maintenance Drive Chain Inspection and Adjustment Regularly lubricate the drive chain with Polaris chain spray lube or an approved chain lube. See page 168 for the part numbers of Polaris products. CAUTION Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure. Don’t use a high pressure washer or gasoline to clean the drive chain.
Maintenance Drive Chain Inspection and Adjustment (90cc Models) 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. Collapse the suspension with an adjustable (buckle type) trailer tie down. Fasten the strap (A) around the axle and rear bumper tube. 3. Tighten the strap until a straight line (B) can be drawn from the rear axle to the gearcase output shaft A intersecting the swing arm pivot. This establishes the tightest chain position. 4.
Maintenance Drive Chain Inspection and Adjustment (50cc Models) 1. Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain. 2. The chain should have 1/4”-1/2” (6-12 mm) deflection. If the chain needs adjustment, use the procedure on page 154.
Maintenance Drive Chain Slack Adjustment CAUTION Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud. 1. Loosen the four rear housing mount bolts (A). 2. Loosen the chain adjuster lock nut. 3. Turn the chain adjuster (B) clockwise to 1/4”-1/2” (6-12 mm) deflection. 4. Tighten the chain adjuster lock nut to 84 in. lbs. (9.4 Nm). 5. Tighten the four rear housing mount bolts to 43 ft. lbs. (60 Nm).
Maintenance Brakelight Lamp Replacement If the brakelight doesn’t work, the lamp may need to be replaced. 1. From the rear of the brakelight, remove the two screws (A) holding the lens cover in place and remove the lens cover (B). 2. Remove the lamp (C) and replace it with a new recommended lamp. 3. Test the brakelight to ensure operation. 4. Reinstall the lens cover.
Maintenance Indicator Light Lamp Replacement 1. 2. 3. 4. 156 Remove the handlebar cover or pod to access the lamps. Use a needle-nose pliers to pinch the tangs and remove the lamp. Apply dielectric grease to the socket and install the new lamp. Reinstall the cover or pod.
Maintenance Daytime Running Lights Lamp Replacement (if equipped) If the daytime running lights do not operate, replace the lamps. Polaris recommends that you install replacement lamps obtained from your authorized Polaris dealer. 1. Predator 90: Locate the lamp socket below the front cover. Rotate the socket counterclockwise about 1/4 turn and remove it from the housing. Sportsman 90: Remove the light housing from the bumper. Separate the housing by removing the four screws from the rear cover.
Maintenance Cleaning and Storage Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing the ATV 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.
Maintenance Cleaning and Storage Waxing the ATV 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. CAUTION Certain products, including insect repellants and chemicals, will damage plastic surfaces. Use caution when using these products near plastic surfaces.
Maintenance Cleaning and Storage Storing the ATV Proper preparation of the engine and fuel system is vital to the prevention of rust and corrosion on engine parts. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged. Use Polaris fogging oil and follow the directions on the can. Always add a fuel conditioner/stabilizer to the fuel tank before storage. Run the engine for five minutes to get the additives through the entire fuel system and then top off with fuel.
Maintenance Cleaning and Storage Transporting the ATV Follow these procedures when transporting the ATV. 1. 2. 3. 4. Turn the fuel valve off. Be sure the fuel cap, oil cap and seat are installed correctly and securely. Tie the frame of the ATV to the transporting unit securely using suitable straps or rope. Lock the parking brake. Accessories Polaris has a wide range of accessories available for your ATV. See your Polaris dealer.
Specifications Rider Capacity/Maximum Weight Displacement Carburetion Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 162 Predator 50 1 Rider/90 lbs. (41 kg) 49cc H68K Air Cooled 2-Stroke Oil Injected 20 oz. (.6 liter) 1 gallon (3.8 liters) Electric with kick-start backup Automatic CVT Chain Single control arm with 3″ (7.6 cm) of travel Spring over shock with 3″ (7.
Specifications Front/Rear Brakes Parking Brake Front Tires Rear Tires Turning Radius (inside tire) Wheel Base Ground Clearance Dry Weight Length/Width/Height Brake Light Low Oil Light Predator 50 Drum Mechanical Lock 16 x 6.5 - 7 (3 psi) 16 x 8 - 7 (3 psi) 60″ (152 cm) 33″ (84 cm) 4″ (10 cm) 185 lbs. (84 kg) 48″ (10 cm) / 31.
Specifications Rider Capacity/Maximum Weight Displacement Carburetion Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 164 Predator 90 1 Rider/165 lbs. (75 kg) 89cc H68K Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liter) 1.3 gallons (5 liters) Electric with kick-start backup Automatic CVT Chain A-arm with 4.25″ (10.8 cm) travel Spring over shock with 5″ (12.
Specifications Front/Rear Brakes Parking Brake Front Tires Rear Tires Turning Radius (inside tire) Wheel Base Ground Clearance Dry Weight Length/Width/Height Brake Light Low Oil Light Predator 90 Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 70″ (178 cm) 38.5″ (98 cm) 5″ (12.7 cm) 262 lbs. (119 kg) 57″ (145 cm) / 35.75″ (91 cm) / 36.1″ (91.
Specifications Rider Capacity/Maximum Weight Displacement Carburetion Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 166 Sportsman 90 1 Rider/165 lbs. (75 kg) 89cc H68K Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liters) 1.32 gallons (5 liters) Electric with kick-start backup Automatic CVT Chain A-arm with 5″ (12.7 cm) of travel Spring over shock with 4.25″ (10.
Specifications Front Rack Capacity Rear Rack Capacity Front/Rear Brakes Parking Brake Front Tires Rear Tires Wheel Base Ground Clearance Turning Radius (inside tire) Dry Weight Length/Width/Height Brake Light Low Oil Light Sportsman 90 10 lbs. (4.5 kg) 20 lbs. (9 kg) Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 38.5″ (98 cm) 5″ (12.7 cm) 70″ (177 cm) 276 lbs. (125 kg) 59.75″ (151.8 cm) / 35.75″ (90.8 cm) / 36.
Polaris Products Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2874438 VES II Synthetic 2-Cycle Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871098 Premium 2-Cycle Engine Oil (qt.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2871653 Premium ATV Angle Drive Fluid (8 oz.) 2871654 Premium Demand Drive Hub Fluid (8 oz.) Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.
Polaris Products Part No. Description Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium All Season Grease (14 oz. cartridge) 2871460 Starter Drive Grease (2 oz.) 2871515 Premium U-Joint Lube (3 oz.) 2871551 Premium U-Joint Lube (14 oz.) 2871329 Dielectric Grease (Nyogelt) 2872073 Chain Lube, Aerosol (6.25 oz.) 2872348 Chain Lube, Aerosol (16 oz.
Troubleshooting See your Polaris dealer if you’re unable to identify solutions using the following charts.
Troubleshooting Engine Doesn’t Turn Over Possible Cause Solution Low battery voltage Recharge battery with .
Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer 172
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with .
Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect, clean and/or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer 174
Troubleshooting Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery volta
Warranty LIMITED WARRANTY Polaris Sales 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 in material or workmanship. Polaris also gives a one year limited warranty 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.
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.
Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY.
Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service.
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. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you have any questions.
Warranty EXPORTED VEHICLES How to Get Service If You Move: If you move to another country, be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. Vehicles importation rules vary considerably from country to country. You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage.
Index A D F Air Cleaner . . . . . . . . . . . . . . . . . . . 142 Axle and Wheel Nut Torque Specs . 134 Daily Pre-Ride Inspection . . . . . . . . . 90 Daytime Running Lights . . . . . . . . . 159 Drive Chain Adjustment . . . . . . 151-153 Driver Warnings . . . . . . . . . . . . . . 47-69 Driving Across Hillsides . . . . . . . . . 102 Driving Downhill . . . . . . . . . . . . . . 106 Driving in Reverse . . . . . . . . . . . . . . 111 Driving on Slippery Surfaces . . . . . . 98 Driving Over Obstacles . .
Index L-M R T Lamp Replacement Brakelights . . . . . . . . . . . . . . 155 Daytime Running Lights . . . . 157 Indicator Lights . . . . . . . . . . 156 Lights . . . . . . . . . . . . . . . . . . . . . . . . 81 Lubricants, 2-Cycle . . . . . . . . . . . . . 128 Lubrication Recommendations . 126-129 Main Switch . . . . . . . . . . . . . . . . . . . 71 Maintenance . . . . . . . . . . . . . . . 116-161 Maintenance Chart Key . . . . . . . . . 122 Maintenance Record . . . . . . . . .
