Polaris Sportsman 90 Guide

WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.

Indicates a potential hazard which
could result in severe injury or death.

i
PARENTS: Review the information in this manual with any child who may be
operating the ATV. It is up to you to teach your child the proper and safe way
to ride an ATV. You must set boundaries and adhere to them, keeping your
child’s safety foremost in your mind. Never allow your child to operate this
machine without adult supervision.
CHILDREN: Before you ride your new Polaris ATV, there are some important
things you should know. How to keep safe is the most important thing. You
must also learn some things that will keep you and those around you safe while
you are riding.

ii

iii
FOREWORD
Congratulations and thank you from Polaris Industries Inc. for purchasing one of our
all-terrain vehicles (ATVs). It is designed to provide superior riding comfort, enjoy-
ment, and safety.
This manual is furnished to ensure that the operator and parents are aware of safe
operating procedures. It also includes information about the general care and main-
tenance of your ATV.
Carefullyread the following pages. If you have any questions regarding this ATV con-
tact a Polaris dealer for assistance. Remember, Polaris dealers have the knowledge
and facilities to provide you with the best service possible.

iv
PROTECT YOUR SPORT
Know all local, state/province riding laws;
Respect your vehicle;
Respect the environment; and
You will gain the respect of others.
We also advise you to strictly follow the recommended maintenance program as out-
lined. This preventive maintenance program is designed to ensure that all critical
components on this ATV are thoroughly inspected at various intervals.
All information in this manual is based upon the latest product data and specifications
available at the time of printing. Polaris Industries Inc. reserves the right to make
product changes and improvements which may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written permission of
Polaris Industries Inc.
Illustrations included in this manual are general representations of parts
having a similar function. Your model may differ.

v
INTRODUCTORY SAFETY MESSAGE TO PARENTS
AN ATV IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. An ATV handles
differently from other vehicles including motorcycles and cars. A collision or rollover
can occur quickly, even during routine maneuvers such as turning and driving on hills
or over obstacles, if you fail to take proper precautions.
Children differ in skills, physical abilities, and judgement. Some children may not be
able to operate an ATV safely. Parents should supervise their child’s use of the ATV
at all times. Parents should permit continued use only if they determine that the child
has the ability and maturity to operate the ATV safely.
Failure to follow the warnings contained in this manual can result in
SERIOUS INJURY or DEATH.
•Read this manual and all labels carefully and follow the operating procedures de-
scribed.
•Never operate an ATV without proper instruction. Take a training course. Riders
should receive training from a certified instructor. Contact an authorized Polaris
ATV dealer or call Polaris at 1-800-342-3764 to find out about the training courses
nearest you.

vi
•Always follow the age guidelines for your machine. Youth ATVs are designed and
intended for use by children in two age groups. The Scrambler 50 is for children
not less than 6 years of age. The Scrambler 90 and the Sportsman 90 are for chil-
dren not less than 12 years of age. No children under the age of 16 should ride an
ATV designed and sold for an adult.
•Do not allow other children to ride this ATV unless they have read the manual, seen
the instructional video and taken and passed a Polaris approved riding skill test.
•Always avoid operating an ATV on any paved surfaces, including sidewalks, drive-
ways, parking lots and streets.
•Never operate an ATV on any public street, road or highway, even a dirt or gravel
one.
•Never operate an ATV without wearing an approved helmet that fits properly. You
should also wear eye protection (goggles or face shield), gloves, boots, long-
sleeved shirt or jacket, and long pants.
•Never consume alcohol or drugs before or while operating this ATV.
•Never operate at excessive speeds. Always travel at a speed which is proper for
the terrain, visibility and operating conditions, and your experience.

vii
•Never attempt wheelies, jumps or other stunts.
•Always inspect your ATV each time you use it to make sure it is in safe operating
condition. Always follow the inspection and maintenance procedures and sched-
ules described in this manual.
•Always keep both hands on the handlebars and both feet on the footrests of the
ATV during operation.
•Always go slowly and be extra careful when operating on unfamiliar terrain. Always
be alert to changing terrain conditions when operating the ATV.
•Never operate on excessively rough, slippery or loose terrain.
•Always follow proper procedures for turning as described in this manual. Practice
turning at low speeds before attempting to turn at faster speeds. Do not turn at ex-
cessive speed.
•Always have the ATV checked by an authorized Polaris dealerif it has been involved
in an accident.
•Never operate the ATV on hills too steep for the ATV or for your abilities. Practice
on smaller hills before attempting larger hills.

viii
•Always follow proper procedures for climbing hills as described in this manual.
Check the terrain carefully before you start up any hill. Never climb hills with exces-
sively slippery or loose surfaces. Shift your weight forward. Never open the throttle
suddenly or make sudden gear changes. Never go over the top of any hill at high
speed.
•Always follow proper procedures for going down hills and for braking on hills as de-
scribed in this manual. Check the terrain carefully before you start down any hill.
Shift your weight backward. Never go down a hill at high speed. Avoid going down
a hill at an angle which would cause the vehicle to lean sharply to one side. Go
straight down the hill where possible.
•Always follow proper procedures for crossing the side of a hill as described in this
manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight
to the uphill side of the ATV. Never attempt to turn the ATV around on any hill until
you have mastered the turning technique described in this manual on level ground.
Avoid crossing the side of a steep hill if possible.

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•Always use proper procedures if you stall or roll backwards when climbing a hill.
To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll
backwards, follow the special procedure for braking described in this manual. Dis-
mount on the uphill side or to either side if pointed straight uphill. Turn the ATV
around and remount, following the procedure described in this manual.
•Always check for obstacles before operating in a new area. Never attempt to oper-
ate over large obstacles, such as large rocks or fallen trees. Always follow proper
procedures when operating over obstacles as described in this manual.
•Always be careful of skidding orsliding. On slippery surfaces, such as ice, go slowly
and be very cautious in order to reduce the chance of skidding or sliding out of con-
trol.
•Avoid operating the ATV through deep or fast flowing water. If you cannot avoid
water which exceeds the recommended maximum depth (pg. 98), go slowly, bal-
ance your weight carefully avoiding sudden movements, maintain a slow and
steady forward motion, do not make sudden turns or stops, and do not make sud-
den throttle changes.
•Wet brakes may have reduced stopping ability. Test your brakes after leaving water.
If necessary apply them lightly several times to let friction dry out the pads.

x
•Always use the size and type tires specified in this manual. Always maintain proper
tire pressure as described in this manual.
•Never modify an ATV through improper installation or use of accessories.
•Never exceed the stated load capacity for an ATV. Cargo should be properlydistrib-
uted and securely attached. Reduce speed and follow instructions in this manual
for carrying cargo. Allow greater distance for braking.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safe-
ty Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
Additional Important Information...
Due to our concern for the safety of our customers and the general public, Polaris
hereby strongly recommends and requests that consumers not have installed on a
Polaris ATV any equipment which is intended to increase the speed or power of the
vehicle; ormake any other modifications to the vehicle for these purposes. Any modi-
fications to the original equipment of the ATV substantially increase the risk of bodily
injury. Please be aware that these modifications may create a substantial safety haz-
ard.

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Polaris hereby informs you that the warranty on your ATV is terminated if any such
equipment has been added to the ATV or any modifications have been made to the
ATV which increase its speed or power.
We also advise you tostrictly follow the recommended maintenance program outlined
in this manual. This preventive maintenance program is designed to ensure that all
critical components on the ATV are thoroughly inspected by your dealer at various
mileage intervals.
NOTE:
The addition of certain accessories may change the handling characteristics of the
ATV.
Be certain any accessories added to this ATV have been approved by Polaris.
Familiarize yourself with their function and affect on the ATV.
Indicates a potential hazard which could
result in severe injury or death.

xii
TABLE OF CONTENTS
RIDER’S SECTION R-1 - R-20...............................................
UNDERSTANDING WARNINGS 1 - 4........................................
GENERAL SAFETY AND DESCRIPTION OF LABELS 5-19.....................
DAILY PRE-RIDE CHECK 20-21.............................................
OPERATION WARNINGS 22-46.............................................
VEHICLE IDENTIFICATION NUMBERS 47-48.................................
CONTROL AND PARTS FUNCTIONS 49-69..................................
STARTING THE ENGINE 70-71.............................................
RIDING GEAR 72-73.......................................................
VEHICLE BREAK IN PERIOD 74-76.........................................
CARRYING LOADS 77-80..................................................
DAILY PRE-RIDE CHECK 81-83.............................................
RIDING 84-103............................................................

xiii
TABLE OF CONTENTS
PVT SYSTEM OPERATION 104-105.......................................
BATTERY 106-111.......................................................
NOISE EMISSION CONTROL SYSTEM REGULATION 112-114...............
MAINTENANCE 115-163..................................................
SPECIFICATIONS 164-170................................................
WIRING DIAGRAMS 171-172.............................................
TROUBLE SHOOTING 173-174...........................................
WARRANTY 175-180.....................................................
INDEX -................................................................

R--1
RIDER’S SECTION

R--2
KNOW YOUR MACHINE
PARENTS: Review the information in this manual with any child who may be
operating the ATV. It is up to you to teach your child the proper and safe way
to ride an ATV. You must set boundaries and adhere to them, keeping your
child’s safety foremost in your mind. Never allow your child to operate this
machine without adult supervision.
Polaris Youth ATVs are equipped with an Adjustable Throttle Stop System and
Exhuast System Restrictor(s) to allow adults to limit the speed of the vehicle
according to the rider’s skill and experience. More information on speed limiting
functions can be found on pages 134-136 in the maintenance section of this
manual.
CHILDREN: Before you ride your new Polaris ATV, there are some important
things you should know. How to keep safe is the most important thing. You
must also learn some things that will keep you and those around you safe while
you are riding.

R--3
KNOW YOUR MACHINE
Pay attention when you see this symbol.:
This is the safety alert symbol. When you see this symbol on your
machine or in this manual it means PAY ATTENTION. If you don’t,
you could get hurt very badly or even killed. Your safety is in-
volved!

R--4
KNOW YOUR MACHINE
Before you have an adult start the engine for you for the first time, let’s learn
about the controls on your new machine.
1. Engine Stop Switch (A) - When the
engine is running, you can push this
button down to shut the engine off.
The button should be up “on” before
starting the engine.
2. Throttle Control (B) - This makes your
ATV go forward when you press it with
your thumb. You must always make
sure the throttle control does not stick
before you operate your ATV. Read
more about it on page R--12.
1
2
B
A