2007 Polaris Outlaw 90 Owners Manual

2007 Polaris Outlaw 90 Manual

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  • 2007 Polaris Outlaw 90 | Owners Manual - Page 1
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    the State of California to cause cancer, birth defects or other reproductive harm. 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.
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    Visit us at www.polarisindustries.com 1
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    the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in Taiwan 2007 Outlaw 90/Sportsman 90 ATV Owner's Manual P/N 9920868 2
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    ATV without adult supervision. The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child's vehicle, be sure to follow all of the instructions and recommendations in this manual. If you have any questions about the ATV, contact a
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    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
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    Pre-Ride Inspections ...85 Starting the Engine ...88 Stopping the Engine ...91 Driving Safely ...92 Emission Control ...112 Maintenance ...114 Specifications ...178 Polaris Products ...182 Troubleshooting ...184 Warranty ...190 Maintenance Log ...198 Index...202 Table of Contents 5
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    . Make sure all operators have completed an approved ATV safety training course such as the SVIA RiderCoursesm and 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
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    who will be riding the ATV to take the ATV RiderCoursesm. 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. If you purchased a used Polaris ATV, you can
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    are used. Become familiar with their meanings before reading the manual. CAUTION The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety damage to the vehicle. NOTE: A note will alert you to important information or instructions. 8
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    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 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. 9
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    ride any ATV designed and sold for an adult. 10 • 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 such as the ATV RiderCoursesm. • Always avoid operating an ATV on
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    time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules 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
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    follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before you start up any hill procedures for going down hills and for braking on hills as described in this manual. Check the terrain carefully before you start down any hill. Shift your weight
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    . Dismount 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 be careful of skidding or sliding. On slippery surfaces, such as ice, go slowly and be very cautious in order to reduce the chance
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    to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual. • Avoid operating the ATV through deep or fast flowing water. If you cannot avoid water which exceeds the recommended maximum depth (see page
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    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
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    16
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    Youth Section 17
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    riding. Pay attention when you see this symbol: This is the safety alert symbol. When you see this symbol on your ATV or in this manual it means PAY ATTENTION because you could die or be seriously injured if you don't follow the
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    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.
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    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 82. 5. Shift Lever - The shift lever is on the right
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    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. Always have an adult put gas in your ATV. Never try to do it yourself. 6. Gas Cap 7. Seat Latch - The seat latch is under the left edge
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    Know Your ATV 8. Brake Levers - Squeeze the brake levers toward the handlebar to slow down or stop the ATV. The left lever controls the rear brake. The right lever controls the front brake. Always squeeze both brake levers at the same time. Always squeeze both brake levers at the same time or you
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    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
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    Know Your ATV Let's review the three ways to stop the engine of your ATV: 1. Push the engine stop switch down. 2. Pull the tether strap off the ATV. 3. Turn the key off. 24
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    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
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    must never add their own gasoline. This must always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 78 of this manual. Always have an adult put gas in your ATV. Never try to do it yourself. 26
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    Pre-Ride Check n If you used the storage area under the seat, make sure the seat is locked in place. n 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
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    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. X The adult with you is
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    Riding Rules X Always wear the right kind of clothing and safety gear when riding your ATV. Long Helmet Helmet: Your helmet is very important for safe riding. A Sleeves helmet can prevent a severe head injury. Eye Protection: Always wear shatterproof goggles or a helmet face shield, and always keep
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    Riding Rules X Always attach the tether strap to your right wrist and to the ATV before riding. X 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. X Your ATV is made for one person. Never carry a passenger. A passenger will
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    Riding Rules X Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. X Never ride on public trails. X 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
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    Respect your ATV; respect your environment; and you will earn the respect of everyone. Enjoy riding your new Polaris ATV! 32
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    Adult Section 33
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    have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If any of the decals shown in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes
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    . 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 and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR
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    increased chance of losing control, which could result in severe injury or death. • Adult supervision is required. • Make sure operators follow Owner's Manual and labels. • Make sure operators watch the safety video or DVD and complete the ATV RiderCoursesm. • Never operate this ATV on HILLS steeper
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    Outlaw 90 Tire Pressure Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE IN PSI (KPa): FRONT 3 (20.7) REAR 3 (20.7) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 453 LBS. (206
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    best. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information. + 38
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    No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Safety Decals + + 39
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    Safety Decals Sportsman 90 Rack Warning WARNING DO NOT TOW WITH THIS VEHICLE. Vehicle damage or tipover may result causing severe injury or death. Maximum Rack Loads: Front 15 lbs. (6.8 kg) Rear 30 lbs. (13.6 kg) + + 40
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    Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not touch clutch cover, cover may become hot. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive
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    42
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    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. Be sure to explain to your young driver that the following hazards MUST be avoided at all times. 43
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    WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident the skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800)
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    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 49
    Driver Warnings WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces your ability to balance and control this ATV. Carrying a passenger could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never
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    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
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    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 paved or unpaved public street, road or highway. In many states it is illegal to operate ATVs
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    Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV without wearing protective gear. WHAT CAN HAPPEN Operating without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection and protective clothing can also result
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    Driver Warnings WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Your judgment could be seriously affected. You may react more slowly. Your balance and perception will be affected. You could have an accident. HOW TO AVOID THE HAZARD Never consume alcohol
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    use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 51
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    Driver Warnings WARNING POTENTIAL HAZARD Attempting 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 jumps, or other stunts. Avoid exhibition driving (don't show off). 52
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    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 make it harder 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,
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    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. This could cause the ATV to overturn or go out of control. HOW TO AVOID THE HAZARD Go
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    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
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    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. WARNING POTENTIAL HAZARD Towing or pulling
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    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 98. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose surfaces
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    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 104. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any
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    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 102. Use extra caution when turning on any hill. Avoid crossing the side of a steep hill. When crossing the side of a hill: Always
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    . Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. See page 102. 60
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    large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. 61
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    pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner's manual for the ATV. Always maintain proper tire pressure as stated in the specifications section of the owner
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    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
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    vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. 64
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    . WARNING Damaged components can cause loss of control resulting in serious injury or death. After a rollover or an accident, have a qualified service dealer check the complete vehicle including, but not limited to, brakes, throttle and steering for possible damage. WARNING Leaving the keys in the
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    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. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one of your existing
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    Main Key Switch Features and Controls Turn the key clockwise to the ON position before starting the engine. To avoid draining the battery, always turn the key to the OFF position when the engine is not running. Key Key OUTLAW SPORTSMAN WARNING Leaving the keys in the ignition can lead to
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    Features and Controls Engine Stop Switch Horn Stop Switch 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
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    Horn Button Engine Start Button Features and Controls Use the horn for emergencies and to let others know you're near. The start button is located slightly above the choke lever 1. Attach the tether strap securely to the vehicle and to the rider's right wrist. 2. Shift the transmission to neutral.
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    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
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    Throttle Lever Press the throttle lever toward the handlebar to increase engine speed and vehicle movement. 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
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    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. Shift Pattern Shift Lever F: Forward Gear N: Neutral R: Reverse F N R 72
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    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
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    Features and Controls Brakes Squeeze both brake levers toward the handlebar at the same time to apply the brakes. The left lever controls the rear brakes. The right lever controls the front brakes. Rear Brakes Front Brakes WARNING Applying only one brake could cause loss of control and result in
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    Brakes Parking Brake Features and Controls Not Locked Locked 1. Squeeze the left brake lever. 2. Push the parking brake lock down to lock the brake lever in place. 3. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release automatically. WARNING
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    Features and Controls Brakes Parking Brake 1. Always shift the transmission to neutral and lock the parking brake before starting the engine. 2. After the engine has warmed enough for operation, shift to the desired gear. 3. Release the parking brake and gently apply the throttle. 4. Always lock
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    Lights Features and Controls 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
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    Features and Controls Fuel System WARNING Gasoline is highly flammable and explosive under certain conditions. • 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
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    Fuel System Features and Controls 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. 79
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    Features and Controls Fuel System Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane of 87. Refer to the specifications section beginning on page 178 for fuel tank capacity. Gas Cap 80
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    Fuel Valve The fuel valve is located on the left side of the ATV. It has three settings. OFF: For vehicle storage and when transporting. ON: For normal operation. RES: For reserve supply if main supply is exhausted. NOTE: The reserve setting allows Features and Controls Sportsman 90 Fuel Valve
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    -Start Lever If the battery becomes too weak to start the engine, use the kick-start lever to start the engine until the battery is serviced. 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Lock the parking brake. 4. Fold out the kick-start lever on the left side
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    Break-in Period The break-in period for your new Polaris 4-cycle ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of
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    Break-in Period 1. Fill the fuel tank with gasoline. See page 78. 2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the proper range. See page 125. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and
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    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. Pre-Ride Checklist Item Brake system / lever travel Front suspension Rear suspension Steering
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    Pre-Ride Inspection Pre-Ride Checklist Item Tires Wheels / fasteners Fuel and oil Throttle Engine stop switch Brakelight Remarks Check condition and pressure Inspect, ensure fastener tightness; check that axle nuts are secured by cotter pins Check and fill as needed Check for proper operation Check
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    Pre-Ride Inspection Pre-Ride Checklist Item Air filter, pre-filter Drive chain Frame nuts, bolts, fasteners Loose or damaged components Riding gear Remarks Inspect, clean or replace Check condition and slack; refer to drive chain adjustment Inspect, ensure tightness Visually inspect for any damaged
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    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
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    Starting the Engine 1. 2. 3. 4. Shift the transmission to neutral. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle and attach the tether strap to the ATV and to your right wrist. the lever is pushed completely to the right. The choke can be adjusted gradually, depending on how
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    Starting the Engine 8. Squeeze the rear brake lever and press the starter button. NOTE: The rear brake lever must be engaged or the engine won't start. 9. Activate the starter for a maximum of five seconds, releasing the button when the engine starts. If it doesn't start, release the starter, wait
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    Stopping the Engine 1. Release the throttle completely and brake to a complete stop. 2. Shift the transmission to neutral. 3. Stop the engine. NOTE: There are three ways to stop the engine. • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off the ATV. NOTE: To avoid
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    Driving Safely 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 Helmet Long Sleeves Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear
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    Riding Gear Eye Protection Driving Safely 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
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    Driving Safely Driving Procedure 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Shift the transmission to neutral. 3. Start the engine and allow it to warm up. 4. Check your surroundings and determine your path of travel. 5. Squeeze the left brake lever. 6.
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    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. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. NOTE
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    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
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    Driving on Slippery Surfaces 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
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    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. 98
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    Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the footrests. 4. Transfer your weight forward. 5. Proceed at a steady rate of speed and throttle opening. 6. Remain alert and be prepared to
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    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. 100
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    Driving Across Hillsides 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
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    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 106
    Turning Around on a Hill 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.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 107
    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 108
    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. Lock the parking brake. 3. Always block the rear wheels on the downhill side as shown in the illustration. 4. Turn the fuel valve off. Driving
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 109
    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. Follow these procedures when operating through water: 1. Determine water depths before driving through water. 2. If crossing a
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 110
    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 114. The following areas need special attention: engine oil, gearcase oil, front and rear gearcases
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 111
    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 112
    injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual. Always back slowly. 109
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 113
    . WARNING Hauling cargo improperly can may cause loss of control and result in serious injury or death. Always carry cargo as instructed in safety decals and in the owner's manual. • Place 1/3 of the cargo weight on the front rack and 2/3 on the rear rack. Carrying loads on only one rack increases
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 114
    Hauling Cargo Driving Safely • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section beginning on page 178. • Secure all cargo before driving. Loose cargo may move or shift, which could cause loss of control or a tipover. Use suitable tie-downs or
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 115
    Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands. Operation of
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 116
    Exhaust Emission Control System Emission Control Systems The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 117
    based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently. Record maintenance and service in the Maintenance Log beginning on page 198. 114
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 118
    need for replacement parts, use genuine Polaris parts available from your Polaris dealer. NOTE: Service and adjustments are critical. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Severe Use Definition Frequent immersion
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 119
    the procedures marked with a Q could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key Perform these operations more often under severe use, such as in dirty or wet conditions, to purge water or dirt
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 120
    Periodic Maintenance Chart Item Steering Front suspension Rear suspension Tires X Brake lever travel Brake system Wheels/fasteners Frame fasteners X XE X Engine oil level Air filter, pre-filter & main element Air box sediment tube Headlamp/tail lamp Maintenance Remarks Check each day before
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 121
    Monthly Monthly Monthly Monthly 100 (160) 100 (160) 100 (160) 100 (160) X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 122
    Periodic Maintenance Chart Item Battery X X X X QE Engine oil change Transmission oil Oil pre-filter screen General lubrication Valve clearance Carburetor float bowl QE QE Throttle cable/ETC switch Choke cable Maintenance Remarks Check terminals; clean; test Drain and change the oil Drain and
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 123
    every two years Change filter Inspect Inspect Inspect Remarks See Page ----129 ---- X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 124
    Periodic Maintenance Chart Item Wiring Clutches (drive and driven) Front wheel bearings Spark arrestor Q Toe adjustment Maintenance Remarks Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Inspect; clean; replace worn parts Inspect; replace as
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 125
    Maintenance Item Engine Oil Lubrication Guide Lube Polaris Synthetic Youth Oil or Synthetic SAE 40 Method See page 124. See page 130. Gearcase (Transmission) Premium AGL Synthetic Oil Level Gearcase Lube
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 126
    Lubrication Guide Maintenance Grease Points Grease Points 123
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 127
    Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 114. Oil may need to be changed more frequently if Polaris oil is not used. Do not use automotive oil. See page 182 for the part numbers of
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 128
    Engine Oil Check Maintain the oil level within the safe range on the dipstick. Do not overfill. 1. Position the vehicle on a level surface. 2. Remove the dipstick. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely. 4. Remove the dipstick and check the oil level. NOTE: A rising oil
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 129
    Maintenance 1. 2. 3. 4. Engine Oil Change Position the vehicle on a level surface. Clean the area around the pre-filter plug. Start the engine. Allow it to idle for two to three minutes. Stop the engine. CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 130
    Engine Oil Change 5. Place a drain pan under the engine crankcase. 6. Remove the pre-filter plug. Allow the oil to drain completely. 7. Wash the oil pre-filter screen with solvent to remove debris. Allow the screen to air dry. 8. Clean the pre-filter plug. Install a new sealing washer on the plug.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 131
    Maintenance Engine Oil Change 10. Reinstall the pre-filter drain plug. Torque to 11 ft. lbs. (15 Nm). 11. Remove the dipstick. Add 29 oz. (850 ml) of the recommended oil. Do not overfill. NOTE: See the specifications section beginning on page 178 for capacities. Reinstall the dipstick. Start the
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 132
    Fuel Filter Maintenance The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. Do not attempt to clean the fuel filter. 129
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 133
    Maintenance Transmission Oil Check The gearcase fill plug is located on the side of the gearcase on the right side of the ATV. Maintain the oil level at the bottom of the fill plug hole threads. Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 134
    Transmission Oil Change 1. 2. 3. 4. 5. 6. Maintenance Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm). Add the
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 135
    Maintenance Spark Plugs Refer to the specifications section beginning on page 178 for spark plug and gap specifications. CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition is indicative of engine operation
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 136
    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 carburetor/throttle
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 137
    Maintenance Cylinder Head Torque Have your dealer check the ATV cylinder head for proper torque at the first service, or after 25 hours. Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the vehicle is not thoroughly inspected. Take
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 138
    . 9. Turn the fuel valve on. 10. Attempt to start the engine. If necessary, repeat the drying procedure. 11. Take the ATV to your dealer for service as soon as possible, whether you succeed in starting it or not. NOTE: If water has been ingested into the transmission, follow the procedure on
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 139
    (CVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual. This CVT system is intended for use on Polaris products only. Do not install
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 140
    water is accidently ingested into the CVT system. Use the following instructions to dry it out before operating. The drain plug is the belt slips, repeat the process. 6. Take the vehicle to your dealer for service as soon as possible. CAUTION Exposure to salt water will cause corrosion to metal
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 141
    Periodic Maintenance Chart beginning on page 114. WARNING Failure to heed these warnings could result in serious injury or death. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Wear eye protection and gloves. Never run
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 142
    Spark Arrestor 1. Remove the three bolts and remove the arrestor from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 3. Inspect the screen for wear
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 143
    Maintenance Carburetor IMPORTANT: 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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 144
    Carburetor Maintenance If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted. 1. Start the engine. 2. Lock the parking brake. 3. Allow the engine to run for approximately five minutes. 4. Adjust the carburetor idle screw either in or
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 145
    Maintenance Speed Control System 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 50cc models and under 15 MPH for the 90cc models. The dealer CANNOT, under any circumstances, either prior to the sale or later, even at
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 146
    Speed Control System Throttle Stop Speed Control System Maintenance Jam Nut Screw Use the following procedure to control how far the throttle opens. 1. Loosen the jam nut. 2. Turn the screw inward to reduce speed or outward to increase speed. 3. Tighten the jam nut after adjusting. 143
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 147
    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" (1.5 - 3.2 mm). If adjustment is required, turn the adjustment nut until the freeplay falls in to the acceptable
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 148
    Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals recommended in the Periodic Maintenance Chart beginning on page 114. If the freeplay isn't at specification, adjust the freeplay as outlined on the following pages. Brake Freeplay Specifications Model 90cc
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 149
    Maintenance Brake Freeplay Front Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the front of the vehicle by placing a suitable stand under the frame. The front tires should be slightly off the ground. 4. While rotating the left front
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 150
    Brake Freeplay Maintenance Front Brake Adjustment 6. While rotating the right front wheel, tighten the lower front brake adjuster nut on the right-hand control. 7. When you begin to feel a slight drag in wheel rotation, loosen the adjuster nut one full turn. 8. Verify that the right-hand brake
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 151
    Maintenance Brake Freeplay Rear Brake Adjustment 1. Position the vehicle on a level surface. 2. Shift the transmission to neutral. 3. Elevate the rear of the vehicle by placing a suitable stand under the frame. The rear tires should be slightly off the ground. 4. While rotating the rear wheels,
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 152
    specifications can no longer be obtained through adjustment as outlined on the preceding pages, use the following information to determine when to service the brakes. Service the brakes when brake lever travel reaches the total lever travel measurement listed in the Measure table below. Always
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 153
    Maintenance 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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 154
    the front rim. Rear measurement should be 1/16" - 1/8" (2-3 mm) more than the front measurement. NOTE: If you discover improper alignment, see your Polaris dealer for service. Maintenance Measure to rim Stands 151
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 155
    Maintenance Steering Inspection Check the steering assembly periodically for loose nuts and bolts. If any are found, have your dealer tighten them before operating the ATV. Camber and Caster The camber and caster are non-adjustable. Shock Spring Adjustment The front and rear shock absorber
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 156
    Drive Chain Maintenance Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the general lubrication interval specified in the Periodic Maintenance Chart beginning on page 114. Lubricate more often under severe use, such as in dirty or wet conditions. See page 182
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 157
    Maintenance Drive Chain Slack 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 strap. Fasten the strap around the axle and rear bumper tube. 3. Tighten
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 158
    Drive Chain Slack Adjustment Maintenance CAUTION Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud. 1. Loosen the four rear housing mount bolts. 2. Loosen the chain adjuster lock nut. 3. Turn the chain adjuster clockwise to 1/4"-1/2" (6-12 mm) deflection. 4.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 159
    dry. If the filter is damaged, install a new foam filter. 4. Apply a commercially available foam filter lubricant to the foam filter. Clips 156 Cover Foam Filter Support Screen
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 160
    Air Filter 5. Clean away any oil or sediments in the air box. 6. Reinstall the filter and air box cover. Secure the clips. 7. Reinstall the seat. Maintenance CAUTION Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear and severe damage to the engine
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 161
    , resulting in loss of control and possible serious personal injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. The handlebars can be adjusted for rider preference. 1. Remove the pod to access the handlebar bolts. Loosen the four bolts. 2. Adjust the
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 162
    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 163
    Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. 1/8" (3 mm) Wheel Removal 1. Stop the engine and lock the parking brake. 2. Loosen the wheel bolts slightly. 3. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 164
    Wheel Installation Maintenance 1. Lock the parking brake. 2. 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. 3. Install the wheel bolts and finger tighten them. 4. Lower the
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 165
    Axle and Wheel Nuts All nuts with a cotter pin installed must be service by an authorized Polaris dealer. Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. 162
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 166
    Tail Light Lamp Replacement If the brakelight doesn't work, the lamp may need to be replaced. 1. Remove the two screws securing the lens cover. Remove the lens cover. 2. Remove the lamp and replace it with a new recommended lamp. 3. Test the light for proper operation. 4. Reinstall the lens cover.
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 167
    Maintenance 1. 2. 3. 4. 5. 6. Indicator Light Lamp Replacement Remove the handlebar cover or pod to access the lamps. Remove the indicator wire connections from the harness. Remove the nut from the back side of the indicator lamp. Remove the lamp. Apply dielectric grease to the socket and install
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 168
    it clockwise about 1/4 turn. 7. Start the engine to make sure the lights come on. If the lights do not operate, see your Polaris dealer for service. 8. Reinstall the rubber cover, and reconnect the lights to the harness. 9. Reinstall the front cab (Outlaw only). 165
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 169
    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 170
    Battery Battery Removal Maintenance 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. 167
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 171
    Maintenance Battery 1. 2. 3. 4. 5. Battery Installation and Connections Set the battery in its holder. Connect and tighten the red (positive) cable first. Connect and tighten the black (negative) cable last. Attach the hold-down strap. Verify that cables are properly routed. battery that has not
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 172
    Cleaning Maintenance Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products,
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 173
    Maintenance Cleaning Washing the ATV The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 174
    Cleaning Washing the ATV Maintenance If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: • Wheel bearings • Brakes • Radiator •
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 175
    Maintenance Polishing Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. •
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 176
    Storage Exterior Battery Storage Maintenance Make necessary repairs and clean the vehicle as recommended. See page 169. Remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 177
    better starting after the storage period. 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the container for the recommended amount. NOTE: Carbon clean will also reduce the possibility of bacterial growth in the fuel system
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 178
    Storage Engine Oil Maintenance Change the oil. See page 126. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and air filter. Clean the air box. Drain the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 179
    as recommended in the Periodic Maintenance Chart beginning on page 114. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Using suitable supports under the frame, raise the vehicle slightly so that the tires are not touching the ground. 3. Be sure the storage area is well
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 180
    the frame of the ATV to the transporting unit securely with suitable straps or rope. The rack, bumper or handlebars do not offer enough support for tie-down while transporting the unit. Accessories Polaris has a wide range of accessories available for your ATV. Please see your Polaris dealer. 177
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 181
    Specifications Outlaw 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 1 Rider/170 lbs. (77 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 1.7
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 182
    Specifications Outlaw 90 Front/Rear Brakes Parking Brake Front Tires Rear Tires Dry Weight Length/Width/Height Wheel Base Ground Clearance Brake Light Daytime Running Lights Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 283 lbs. (128 kg) 61.25" (156 cm) / 36.75" (93 cm) / 38.5" (98 cm
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 183
    Specifications Sportsman 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 1 Rider/170 lbs. (77 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 2
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 184
    Specifications Sportsman 90 Front Rack Capacity Rear Rack Capacity Front/Rear Brakes Parking Brake Front Tires Rear Tires Dry Weight Length/Width/Height Wheel Base Ground Clearance Brake Light Daytime Running Lights 15 lbs. (6.8 kg) 30 lbs. (13.6 kg) Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 185
    Polaris Products Part Number 2876248 2876249 2872175 2872176 2870791 2873602 2872348 Description Engine Lubricant Synthetic Youth Oil (qt/.95 l) Synthetic Youth Oil (gal/3.8 l) Semi-Synthetic 20W-40 Oil (qt/.95 l) Semi-Synthetic 20W-40 Oil (gal/3.8 l) Fogging Oil, Aerosol Gearcase / Transmission
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 186
    Polaris Products Part Number 2871322 2871423 2871326 Description Grease All Season Premium Grease (3 oz./89 ml) All Season Premium Grease (14 oz./414 ml) Miscellaneous Additives Carbon Clean Plus 183
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 187
    Troubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine Turns Over, Fails to Start Possible Cause Out of
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 188
    Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Troubleshooting Solution Recharge battery with .5 amp charger Check all connections and tighten Check all connections and tighten Engine Pings or Knocks Possible Cause Poor quality or
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 189
    Troubleshooting Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 190
    in fuel Low battery voltage Kinked or plugged fuel vent line Incorrect fuel Clogged air filter Electronic throttle control malfunction Other mechanical failure Troubleshooting Solution Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 191
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Low or contaminated fuel Low octane fuel Clogged fuel filter Incorrect jetting Solution Add
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 192
    gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Electronic throttle control malfunction Other mechanical failure Troubleshooting Solution Turn the fuel valve to reserve, refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 193
    COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. 190
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 194
    for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 195
    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
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 196
    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. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 197
    must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the country where your vehicle
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 198
    where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind. (Vehicles registered to Government officials or military personnel on assignment outside of the country where the vehicle was
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 199
    Warranty U.S.A. EPA Emissions Limited Warranty This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 200
    Warranty U.S.A. EPA Emissions Limited Warranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 201
    Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 10 Hours (Break-in) 40 Hours 50
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 202
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 100 Hours 120 Hours 150 Hours 199
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 203
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 200
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 204
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 201
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 205
    Index Accessories...177 Age Warning ...36 Air Filter ...156-157 Axle and Wheel Nuts ...162 Battery Installation/Connections ...168 Removal ...167 Storage...168, 173 Boots...93 Brake Adjustment, Front ...146-147 Brake Adjustment, Rear ...148 Brake Freeplay ...145-148 Brake Freeplay Specifications ...
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 206
    Lamp Replacement Daytime Running Lights . . 165 Indicator Light ...164 Tail Light ...163 Lights, Indicator ...77 Lights, Daytime Running ...165 Lubrication Guide ...122-123 Main Key Switch ...67 Maintenance Chart ...114-121 Making Turns ...95 Modifications ...15 I-J K No Passenger Warning...39 Oil
  • 2007 Polaris Outlaw 90 | Owners Manual - Page 207
    Index Switches Engine Start Button ...69 Engine Stop Switch ...19, 68 Horn Button...19 Ignition Switch ...23 Main Key Switch...67 Tether Switch ...23 S Tail Light ...163 Tether Strap ...23 Throttle ...70 Throttle Cable Adjustment ...144 Throttle Control ...19 Throttle Lever ...71 Throttle Stop
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