Polaris OUTLAW 90 User manual

Read this manual carefully. It contains important safety information.
Adult supervision is required at all times.
Operation is prohibited for anyone under age 10.
OUTLAW 90
SPORTSMAN 90
Owner's Manual for Maintenance and Safety

A card containing important ATV safety information should be attached to the
owner's manual on the next page. If you cannot locate this card, or if it has been
removed, please call 1-800-342-3764 for assistance.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.

WARNING
Improper vehicle use can result in
SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR
NEVER USE
ON PUBLIC
ROADS
NEVER CARRY
PASSENGERS
NEVER USE
WITH DRUGS
OR ALCOHOL
NEVER operate:
Swithout proper training or instruction
Sat speeds too fast for your skills or the conditions
Son public roads - a collision can occur with
another vehicle
Swith a passenger - passengers affect balance
and steering and increase risk of losing control
ALWAYS:
Suse proper riding techniques to avoid vehicle
overturns on hills and rough terrain and in turns
Savoid paved surfaces - pavement may
seriously affect handling and control
For your nearest Polaris dealer, call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9923967 Rev 01
Printed in Taiwan *9923967 *

1
Visit us at www.polarisindustries.com

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POLARIS, THE WAY OUT, SPORTSMAN and OUTLAW are registered trademarks of POLARIS Industries
Inc.
Copyright 2012 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 produc-
tion 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 liabil-
ity can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures
contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the origi-
nal instructions.
Printed in Taiwan
2013 OUTLAW 90/SPORTSMAN 90 Owner's Manual
P/N 9923967

3
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 learn-
ing about safe operation and care of your new ATV.
A POLARIS ATV is not a toy and can be hazardous to operate. Make sure any child who will
operate the ATV takes a training course before operating the ATV. Make sure all operators
understand and follow all of the instructions and warnings contained in this owner’s manual.
Never allow a child under the age of 16 to operate an ATV without adult supervision. Chil-
dren differ in skills, physical abilities and judgement. Some children may not be able to oper-
ate an ATV safely. Permit continued use only if you determine that your child has the ability
and maturity to operate the ATV safely.
For your child’s safety, be sure your child can reach and operate all ATV controls, including
handlebars, brake levers, throttle lever and engine stop switch.
The preventive maintenance program outlined in this manual is designed to ensure that all
critical components on your child's ATV are thoroughly inspected at specific intervals. Fol-
low all of the instructions and recommendations in this manual.

4
Welcome
Dear Children:
Before you ride your new POLARIS ATV, there are some important things that you need to
know. You must learn how to keep yourself and those around you safe while you're riding.
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. You must also take an
ATV training course before you begin riding.
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. Never drive your ATV alone. Always make sure an adult is
watching you when you ride.
Drive safely and enjoy riding your new POLARIS ATV!

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Table of Contents
Introduction. . . . . . . . . . . . . . . . . 6
Safety. . . . . . . . . . . . . . . . . . . . . . 8
Youth Section . . . . . . . . . . . . . . 39
Know Your ATV . . . . . . . . . . . 40
Pre-Ride Check. . . . . . . . . . . 47
Riding Rules . . . . . . . . . . . . . 50
Adult Section. . . . . . . . . . . . . . . 55
Vehicle ID Numbers. . . . . . . . 56
Features and Controls . . . . . . 57
Operation. . . . . . . . . . . . . . . . 69
Emission Control Systems. . . 96
Maintenance . . . . . . . . . . . . . 98
Specifications. . . . . . . . . . . . 162
POLARIS Products . . . . . . . 167
Troubleshooting . . . . . . . . . . 168
Warranty . . . . . . . . . . . . . . . 174
Maintenance Log . . . . . . . . . 189
Index. . . . . . . . . . . . . . . . . . . . . 193

6
Introduction
Safety Words and Symbols
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 indicates a potential
personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that,
if not avoided, will result in death or serious
injury.
WARNING
A WARNING indicates a hazardous situation
which, if not avoided, could result in death or
serious injury.
CAUTION
A CAUTION indicates a hazardous situation
which, if not avoided, could result in minor or
moderate injury.
NOTICE
A NOTICE indicates a situation that could result
in property damage.
The Prohibition Safety Sign indicates
an action NOT to take in order to avoid
a hazard.
The Mandatory Action Sign indicates
an action that NEEDS to be taken to
avoid a hazard.

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Introduction
Failure to follow the warnings and safety precautions contained 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 this owner’s manual. Understand all
safety warnings, precautions and operating
procedures before operating a POLARIS ATV.
Keep this manual with the ATV.
• Never operate an ATV without proper
instruction. Take a training course.
• For your child’s safety, be sure your child can
reach and operate all ATV controls, including
handlebars, brake levers, throttle lever and
engine stop switch.
• Always follow the age guidelines for your
vehicle. Y-10+ 90cc models are designed for
children not less than 10 years of age and
Y-6+ 50cc models are designed for children
not less than 6 years of age. No child under
the age of 16 should ride any ATV designed
and sold for an adult.
• Never permit a guest to operate the ATV
unless the guest has read this manual and all
product labels and has completed a certified
safety training course.
WARNING

8
Safety
Safety Training
ATV safety training is a top priority for
POLARIS. POLARIS strongly encourages
you and any family members who will be
riding the ATV to take a training course.
If you purchased a new POLARIS ATV in
the United States, your dealer provided
information about the authorized ATV
RiderCoursesm that is available to you and
your eligible family members. This training
is included in the purchase price of your
ATV.
In addition, you were provided with printed
material and a video or DVD that instructs
operators on safe operating procedures. You
should review this information with your
child on a regular basis. Do not allow other
children to ride this ATV unless they have
read the manual, seen the instructional
video or DVD and taken and completed an
approved ATV safety training course.

9
Safety
Safety Training
If you purchased a used POLARIS ATV in
the United States, you can enroll in the ATV
RiderCoursesm for a fee. Call ATV
Enrollment Express at [phone] or
visit www.atvsafety.org.
If you purchased a POLARIS ATV outside
the United States, please contact your dealer
or local law enforcement agencies for infor-
mation about safety training.
FOR MORE INFORMATION ABOUT ATV
SAFETY in the United States, call the
Consumer Product Safety Commission
at 1-800-638-2772, or visit www.cpsc.gov,
visit www.atvsafety.org, or call POLARIS
at 1-800-342-3764.

10
Safety
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.
Helmet
Wearing a helmet can prevent a severe head injury.
Whenever riding a POLARIS vehicle, always wear a
helmet that meets or exceeds established safety stan-
dards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the
ECE 22.05 label. The ECE mark consists of a circle sur-
rounding the letter E, followed by the distinguishing
number of the country which has granted approval. The
approval number and serial number will also be dis-
played on the label.
Helmet
Eye
Protection Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31

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Safety
Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS
vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield.
POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
Boots
The best footwear is a pair of strong over-the-ankle boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with knee-
pads and a jersey with shoulder pads provide the best protection.

12
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 vehi-
cle for these purposes. Any modifications to the original equipment of the vehicle create a
substantial safety hazard and increase the risk of bodily injury.
The warranty on your POLARIS ATV is terminated if any equipment has been added to the
vehicle, or if any modifications have been made to the vehicle, that increase its speed or
power.
The addition of certain accessories may change the handling characteristics of the ATV. Use
only POLARIS-approved accessories, and familiarize yourself with their function and effect
on the ATV.

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Safety
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which
may result in serious injury or death.
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. Be sure to explain to your young driver that the hazards
outlined in this section of the owner’s manual MUST be avoided at all times. See the RIDING RULES
section and the OPERATION section of the owner’s manual for proper operating procedures.
Operator Restrictions/Age Restrictions
This vehicle is for recreational use by young operators under
adult supervision ONLY.
Operation is prohibited for anyone under age 10.
WARNING
UNDER
10

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Safety
Safety Warnings
Operating Without Instruction
Operating this ATV without proper instruction increases the risk of an
accident. The operator must understand how to operate the ATV
properly in different situations and on different types of terrain.
Beginning and inexperienced operators should complete an ATV
training course. They should then regularly practice the skills learned
in the course and the operating techniques described in the Owner's
Manual. See page 8.
Never permit a guest to operate the ATV unless the guest has read
this manual and all product labels and has completed a certified
safety training course.

15
Safety
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive
under certain conditions.
• Never allow a child to refuel or handle
gasoline.
• Always exercise extreme caution whenever
handling gasoline.
• Always refuel with the engine stopped, and
outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks
in or near the area where refueling is
performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank
neck.
• If gasoline spills on your skin or clothing,
immediately wash it off with soap and water
and change clothing.
• Turn the fuel valve off whenever the ATV is
stored or parked. See page 67.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can
cause loss of consciousness or death in a short
time. Never start the engine or let it run in an
enclosed area.
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.

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Safety
Safety Warnings
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in
safe operating condition before operating
increases the risk of an accident. Always inspect
the ATV before each use to make sure it's in safe
operating condition. Always follow all inspection
and maintenance procedures and schedules
described in the owner's manual.
Protective Apparel
Operating this ATV
without wearing an
approved helmet
increases the risk of
a serious head
injury in the event of
an accident.
Operating without
eye protection could
result in an accident
and could increase
the chance of a
serious injury in the
event of an accident.
Always wear an approved helmet that fits
properly. Always wear eye protection (goggles or
face shield), gloves, boots, a long-sleeved shirt
or jacket and long pants.

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Safety
Safety Warnings
Carrying a Passenger
Carrying a passenger greatly reduces the
operator's ability to balance and control the ATV,
which may result in an accident or overturn.
Never carry a passenger on this ATV.
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception. Never
consume alcohol or drugs before or while
operating an ATV.