2012 Polaris Outlaw 90 Owners Manual

2012 Polaris Outlaw 90 Manual

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  • 2012 Polaris Outlaw 90 | Owners Manual - Page 1
    Pantone 419C Owner's Manual for Maintenance and Safety OUTLAW 90 SPORTSMAN 90 Read this manual carefully. It contains important safety information. Adult supervision is required at all times. Operation is prohibited for anyone age 12 and under.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 2
    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.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 3
    APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy 55
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 4
    Visit us at www.polarisindustries.com 1
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 5
    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 original
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 6
    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. Help them also learn to show respect for our environment and for the rights of others while operating the ATV. Never
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 7
    '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. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 8
    ...50 Adult Section...55 Vehicle ID Numbers...56 Features and Controls ...57 Operation...69 Emission Control Systems...96 Maintenance ...98 Specifications ...162 POLARIS Products ...166 Troubleshooting ...168 Warranty ...174 Maintenance Log ...189 Index...193 5
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 9
    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. The Prohibition Safety Sign indicates an action NOT to take in order to avoid
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 10
    the age of 16 should ride • Never operate an ATV without proper any ATV designed and sold for an adult. instruction. Take a training course. • 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. 7
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 11
    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 ATV unless they have read the manual, seen the instructional video or DVD and taken and completed an approved ATV safety
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 12
    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 (800) 887-2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the United States, please contact your dealer or local
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 13
    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 Helmet Long Sleeves Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 14
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 15
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 16
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 17
    Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident. The operator must 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 18
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 19
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 20
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 21
    Safety Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn. Avoid operating the ATV on pavement. ATV tires are
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 22
    Safety Safety Warnings Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, and your experience. Physical Control of the ATV
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 23
    improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 24
    Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 84. Operating on Steep Hills Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 25
    a hill could cause loss of control or overturn. • Always follow proper procedures for traveling down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 87. • Always check the terrain carefully before descending a hill
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 26
    . Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 86. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 27
    . 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 88. 24
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 28
    Safety Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 29
    accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 30
    ATV and should be installed and used according to approved instructions. See your authorized POLARIS ATV dealer for more information. extreme caution and always follow proper operating procedures as outlined in this manual. Skidding or Sliding Skidding or sliding can cause loss of control
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 31
    Safety Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast-flowing water could cause the tires to float, causing loss of control or overturn. Avoid operating through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the height of the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 32
    Safety Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo may cause changes in handling, which could cause loss of control or an accident. Never haul cargo or tow a load with this ATV. Never tow or pull an object behind the ATV. A wagon, sled or other towed object
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 33
    and loss of control. Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Hot Exhaust Systems
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 34
    Safety European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 35
    have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 36
    Never carry passengers. Never use with drugs or alcohol. NEVER operate: without proper training or instruction; at speeds too fast for your skills or the conditions; on public roads - a affect handling and control. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. 7175376  33
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 37
    Safety Safety Labels and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 15 degrees 15. To prevent overturn on hilly terrain, use throttle and brakes gradually and shift weight uphill. REVERSE operation can be dangerous even at low speeds. Steering becomes
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 38
    Safety Safety Labels and Locations Tire Pressure Warning (OUTLAW 90) WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 3.0 psi (20.7 kPa) Rear: 3.0 psi (20.7 kPa) • Maximum Weight Capacity 180
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 39
    Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378   36
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 40
    Safety Safety Labels and Locations SPORTSMAN 90 Rack Warning WARNING • DO NOT TOW. Vehicle damage or tipover may result causing severe injury or death. • Maximum Rack Loads: Front 15 lbs. (7 kg) Rear 30 lbs. (14 kg) 7174556   37
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 41
    Safety Safety Labels and Locations 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 42
    Youth Section 39
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 43
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 44
    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.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 45
    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 68. 5. Shift Lever - The shift lever is on the right
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 46
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 47
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 48
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 49
    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. 46
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 50
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 51
    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 15 of this manual. Always have an adult put gas in your ATV. Never try to do it yourself. 48
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 52
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 53
    Riding Rules Now you're ready to learn about riding your POLARIS ATV. There are some things you can do and there are some things you must never do. Rules are very important when you're driving an ATV. Adults have riding rules, too. The rules help keep us safe when we ride.  The adult with you is
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 54
    Riding Rules  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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 55
    Riding Rules  Always attach the tether strap to your right wrist and to the ATV before riding.  Make sure you know where you're going to drive before your ATV is started. Make sure the area is safe all around your ATV.  Your ATV is made for one person. Never carry a passenger. A passenger will
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 56
    Riding Rules  Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult.  Never ride on public trails.  Don't ride your ATV on roads or over railroad tracks. Your ATV makes noise that will keep you from hearing cars, trucks or
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 57
    Respect your ATV; respect your environment; and you will earn the respect of everyone. Enjoy riding your new POLARIS ATV! 54
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 58
    Adult Section 55
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 59
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 60
    Features and Controls Main Key Switch 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. Always remove the ignition key when the vehicle is not in use. Key Key OUTLAW
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 61
    Features and Controls Engine 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. Both the main switch and the engine stop switch shut
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 62
    Features and Controls Horn Button Use the horn for emergencies and to let others know you're near. Engine Start Button 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.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 63
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 64
    Features and Controls 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 65
    . Shift Maintaining shift linkage adjustment is important Lever to assure proper transmission function. See your dealer if you experience any shifting problems. Shift Pattern F: Forward Gear N: Neutral R: Reverse NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 66
    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. WARNING! Applying only one brake could cause loss of control and result in serious injury or death.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 67
    Features and Controls Brakes Parking Brake Not Locked Locked 1. Squeeze the left brake lever. 2. Push the parking brake lock down to lock the brake lever in place. 3. Release the brake lever. 4. To release the parking brake lock, squeeze and release the brake lever. The parking brake will release
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 68
    Features and Controls Lights WARNING POLARIS Youth ATVs are not equipped with lights that are designed for driving in the dark. Do not operate this ATV after dark. Use caution and drive at reduced speeds in conditions of reduced visibility. This ATV is designed for off-road use only. Do not operate
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 69
    Features and Controls Fuel System Gas Cap Gas Cap The fuel tank filler cap is located directly below the handlebars. Use unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel. Refer to the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 70
    Features and Controls 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. SPORTSMAN 90 Fuel Valve The reserve setting allows operation
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 71
    -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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 72
    , accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner's manual. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 73
    Operation Break-in Period 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline. See page 15. 2. Check the oil level. Add the recommended oil as needed. Maintain the oil level in the proper range. See page 109. 3. Drive slowly at first. Select an open area
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 74
    Operation Break-in Period 5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 72. 6. Perform the following maintenance at the end of the break-in period. Item Engine oil change Oil pre-filter screen Transmission oil Valve
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 75
    Operation Pre-Ride Inspection 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. Pre-Ride Checklist Item Brake system / lever travel Front
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 76
    Operation Pre-Ride Inspection Pre-Ride Checklist Item Throttle Engine stop switch Daytime running lights (if equipped) Brakelight Air filter, pre-filter Drive chain Frame nuts, bolts, fasteners Loose or damaged components Riding gear Remarks Check for proper operation Check for proper function
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 77
    Operation Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 8. 2. Do not allow anyone age 12 and under to operate this vehicle. 3. Never carry a passenger on this ATV. 4. Engine exhaust fumes are poisonous. Never start the engine or let it
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 78
    type of tires specified for your vehicle. Always maintain proper tire pressure. 10. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage. 11. Never operate the ATV on a frozen body of water. 12. Do not touch hot
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 79
    Operation Starting the Engine NOTICE: Operating the ATV immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating. 1. 2. 3. 4. Shift the transmission to neutral. Lock the parking brake. Turn the fuel valve on. Sit on the vehicle. Attach
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 80
    Operation Starting the Engine 7. Turn the ignition key to ON. 8. Squeeze the rear brake lever and press the starter button. The rear brake lever must be engaged or the engine won't start. 9. Do not press the throttle while starting the engine. Activate the starter for a maximum of five seconds,
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 81
    Operation Stopping the Engine 1. 2. 3. 4. Release the throttle completely. Apply the brakes until the vehicle stops moving. Shift the transmission to neutral. Stop the engine. There are three ways to stop the engine: • Turn the key off. • Push the engine stop switch down. • Pull the tether strap off
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 82
    Operation 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. Shift the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 83
    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. Practice
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 84
    Operation Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 85
    Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 82
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 86
    Operation Driving on Slippery Surfaces 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 87
    Operation Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (15 maximum). 3. Always check the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 88
    Operation Driving Uphill 5. Keep both feet on the footrests. 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards. 8. Never go over the top of any hill at high speed. An obstacle, a sharp drop
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 89
    Operation Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Lean
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 90
    Operation Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (15 maximum). 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 91
    Operation Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop the vehicle and lock the parking brake while keeping body weight uphill. 2. Shift the transmission to neutral. 3. Shut off the engine. 4. Dismount on
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 92
    Operation Turning Around on a Hill 7. Lock the parking brake and remount the ATV from the uphill side, keeping body weight uphill. 8. Restart the engine. 9. Squeeze the rear brake lever. 10. Shift the transmission to forward gear. 11. Release the parking brake and drive slowly, controlling speed
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 93
    Operation Parking on a Hill or Incline Avoid parking on a hill or incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 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. 90
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 94
    Operation Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 95
    Operation 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 precautions when operating through water: 1. Determine water depth and current before entering water. 2. If crossing a
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 96
    if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 118, then see
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 97
    Operation Hauling Cargo The SPORTSMAN 90 was designed with racks to carry small loads. Read and follow all of the instructions for hauling cargo on the following pages. Never carry cargo on the OUTLAW 90. WARNING Overloading the vehicle or carrying cargo improperly can alter vehicle
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 98
    Operation Hauling Cargo • Never exceed the weight capacities for the vehicle. Capacities are listed in the specifications section beginning on page 162. • 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 rope to
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 99
    Emission Control Systems Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 100
    Emission Control Systems Exhaust Emission Control System 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.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 101
    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 189. 98
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 102
    reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 103
    result in component failure and cause an accident, which may result in serious injury or death. Always 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 104
    Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Steering Front suspension Rear suspension Tires Brake lever travel Brake system Wheels/fasteners Frame fasteners  E  Engine oil level Air filter, pre-filter & main element Air box sediment tube Daytime
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 105
    Monthly Monthly Monthly Monthly 100 (160) 100 (160) 100 (160) 100 (160)  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service  Have an authorized POLARIS dealer perform these
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 106
    Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Battery E Engine oil change Transmission oil Oil pre-filter screen 20 30 40 40 Calendar Monthly 6M 12 M 12 M Miles (Km) 200 (320) 300 (480) 400 (640) 400 (640) Check terminals; clean; test Drain and
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    M 12 M 12 M 12 M 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) 113 ----  Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service  Have an authorized POLARIS dealer perform these
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 108
    Maintenance Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Hours Wiring 100 Calendar 12 M Miles (Km) 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. Inspect; clean; replace worn parts Inspect; replace
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 109
    Maintenance Lubrication Guide Item Engine Oil Lube POLARIS Synthetic Youth Oil or Synthetic SAE 40 Method See page 108. See page 114. See page 137. Inspect; tighten fasteners;
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 110
    Maintenance Lubrication Guide Grease Points Grease Points 107
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 111
    Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 98. Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. See page 166 for the part numbers of
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 112
    Maintenance 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. Tip: A
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 113
    Maintenance Engine Oil Change 1. 2. 3. 4. 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 burns to skin. Do not allow hot oil to contact skin. 110
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 114
    Maintenance 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 115
    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. See the specifications section beginning on page 162 for capacities. 12. Reinstall the dipstick. 13. Start the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 116
    Maintenance Fuel Filter 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 98. Do not attempt to clean the fuel filter. 113
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 117
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 118
    Maintenance Transmission Oil Change 1. 2. 3. 4. 5. 6. 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 recommended
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 119
    Maintenance Spark Plugs Refer to the specifications section beginning on page 162 for spark plug and gap specifications. NOTICE: 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.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 120
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel system operation
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 121
    engine stops during or after operating in water, restarting WILL result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined below. This procedure will
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 122
    . 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. 12. If water has been ingested into the transmission, follow the procedure on
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 123
    (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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 124
    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. NOTICE: Exposure to salt water will cause corrosion to metal
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 125
    Periodic Maintenance Chart beginning on page 98. WARNING Failure to heed these warnings could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Allow components to cool sufficiently before proceeding. • Wear eye protection and gloves. • Never
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 126
    Maintenance Spark Arrester 1. Remove the six bolts and remove the arrester from the end of the muffler. 2. Use a non-synthetic brush to clean the arrester screen. A synthetic brush may melt if components are warm. If necessary, blow debris from the screen with compressed air. 3. Inspect the screen
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 127
    Maintenance Carburetor 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. 124
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 128
    Maintenance Carburetor If engine idle speed is too high the vehicle will creep. If idle speed is too low the engine will stall. To adjust idle speed, do the following: 1. Lock the parking brake. 2. Start the engine. 3. Allow the engine to warm up for approximately five minutes. 4. Adjust the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 129
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 130
    Maintenance Speed Control System Throttle Stop Speed Control System 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. Jam Nut Screw 127
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 131
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 132
    Maintenance Brake Freeplay Check (measure) the freeplay of the front and rear brakes at the intervals recommended in the Periodic Maintenance Chart beginning on page 98. If the freeplay isn't at specification, adjust the freeplay as outlined on the following pages. Brake Freeplay Specifications
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 133
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 134
    Maintenance Brake Freeplay 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 135
    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,
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 136
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 137
    Maintenance Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 138
    1/4" (3-6 mm) toe out alignment. 5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for service. 135
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 139
    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 springs
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 140
    Maintenance Drive Chain 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 98. Lubricate more often under severe use, such as in dirty or wet conditions. See page 166 for
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 141
    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 tiedown strap. Fasten the strap around the axle and rear bumper tube. 3. Tighten the
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 142
    Maintenance Drive Chain Slack Adjustment 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. Tighten the chain adjuster lock nut to 18 ft. lbs. (25 Nm). Hold the adjuster stud securely while
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 143
    let dry. If the filter is damaged, install a new foam filter. 4. Apply a commercially available foam filter lubricant to the foam filter. Clips Cover Foam Filter Support Screen 140
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 144
    Maintenance 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. NOTICE: Never operate the ATV with the filter element removed. Dirt will enter the engine causing rapid wear and severe damage to the engine.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 145
    , 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 146
    will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. 143
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 147
    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. 4.
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 148
    Maintenance Wheel Installation 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 vehicle
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 149
    Maintenance 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. 146
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 150
    Maintenance 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 151
    Maintenance Indicator Light Lamp Replacement 1. 2. 3. 4. 5. 6. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 152
    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). 149
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 153
    Maintenance Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 154
    Maintenance Battery Battery Removal 1. 2. 3. 4. Disconnect the hold-down straps securing the electrical box and battery in position. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable next. Lift the battery out of the ATV. 151
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 155
    Maintenance Battery Battery Installation and Connections Always install a fully charged battery. Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. If recharging is necessary, use a .5 amp battery charger
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 156
    Maintenance Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, 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 recharge as needed to
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 157
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 158
    Maintenance Cleaning Washing the ATV 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 •
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 159
    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. •
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 160
    Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended. See page 153. Battery Storage 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 161
    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. Carbon clean will also reduce the possibility of bacterial growth in the fuel system. 3. Start
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 162
    Maintenance Storage Engine Oil Change the oil. See page 110. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 163
    as recommended in the Periodic Maintenance Chart beginning on page 98. 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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 164
    tie 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. 3. Wrap the front tie strap through the frame tubes (not through the bumper tubes), or attach a tie-down hook around
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 165
    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/180 lbs. (81.7 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 1.7
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 166
    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/20.7 kPa) 18 x 9.5 - 8 (3 psi/20.7 kPa) 270 lbs. (122.4 kg) 61.25" (156 cm) / 36.75" (
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 167
    Specifications SPORTSMAN 90 Rider Capacity/Maximum Weight Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Fuel Reserve Capacity Starting Drive System Final Drive Front Suspension Rear Suspension 1 Rider/180 lbs. (81.7 kg) 89cc Air Cooled 4-Stroke Wet Sump 30 oz. (900 ml) 2
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 168
    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. (7 kg) 30 lbs. (14 kg) Drum Mechanical Lock 19 x 7 - 8 (3 psi/20.7 kPa) 18 x
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 169
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 170
    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 167
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 171
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 172
    Troubleshooting Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge battery with .5 amp charger Check all connections and
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 173
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 174
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 175
    Troubleshooting Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Low or contaminated fuel Low octane fuel Clogged fuel filter Solution Add or change
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 176
    Troubleshooting Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel Overuse of choke Fouled or
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 177
    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. 174
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 178
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 179
    Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty does not apply to parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 180
    Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES Warranty applies to the product only and does not allow for coverage of personal loss. Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 181
    Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse;
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 182
    Warranty WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 183
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 184
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 185
    POLARIS Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions. This policy does not apply to vehicles registered to government officials or military personnel on
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 186
    must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair. If You Move: If you move to another country, be sure to contact POLARIS
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 187
    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, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 188
    Warranty U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 189
    Warranty U.S.A. EPA Emissions Limited Warranty For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 190
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 191
    responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 192
    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
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 193
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 100 Hours 120 Hours 150 Hours 190
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 194
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 191
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 195
    Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED / COMMENTS 192
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 196
    Index Age Restrictions ...13 Air Filter ...140-141 Axle and Wheel Nuts ...146 Battery ...150-153 Installation and Connections 152 Removal ...151 Storage ...153, 157 Boots ...11 Brake Adjustment, Front ...130-131 Brake Adjustment, Rear ...132 Brake Freeplay ...129-132 Brake Freeplay Specifications .
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 197
    Horn ...59 Horn Button ...41 Indicator Light ...148 Indicator Lights ...65 Instruction, Operating ...14 Key Switch...57 Kick-Start Lever ...42, 68 K-Turn Lights ...65 Lights, Daytime Running ...149 Lights, Indicator...65 Lubrication Guide ...106-107 Main Key Switch ...57 Maintenance Chart ...98-105
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 198
    ...18 Operating on Public Roads...18 Operating on Steep Hills ...21 Operating Over Obstacles ...27 Operating in Deep Water ...28 Operating Without Instruction 14 Physical Control of the ATV . 19 Physical Skills ...30 Protective Apparel ...16 Skidding or Sliding ...27 Slippery Terrain ...25 Stalling
  • 2012 Polaris Outlaw 90 | Owners Manual - Page 199
    Index Switches Engine Start Button ...59 Engine Stop Switch ...41, 58 Horn Button ...41 Ignition Switch ...45 Main Key Switch ...57 Tether Switch ...45 S Tail Light ...147 Tether Strap...45 Throttle ...60 Throttle Cable Adjustment ...128 Throttle Control ...41 Throttle Lever ...61 Throttle Stop
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Owner's Manual for Maintenance and Safety
Read this manual carefully. It contains important safety information.
Adult supervision is required at all times.
Operation is prohibited for anyone age 12 and under.
OUTLAW
90
SPORTSMAN
90
Pantone 419C