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Polaris 9921811 Offroad Vehicle User Manual

1. 58 Stopping the 46 Stopping the Engine 78 Storage 151 154 Switches Engine Start Button 59 Engine Stop Switch 41 58 Horn Button 41 Ignition Switch 45 Main Key Switch 57 Tether Switch 45 Tail Light 142 Tether 45 wwe os 60 Throttle Cable Adjustment 124 Throttle Control 41 Throttle 61 Throttle Stop Speed Control 123 Tire Tread Depth 140 PIES REMI 139 Toe Alignment 130 131 Transmission Oil 110 111 Transporting the ATV 155 Turning Around ona 86 87 Vehicle Identification Numbers 56 Vehicle Immersion 114 115 Warranty 172 173 Warranty Emissions 172 173 Washing the ATV 148 Wheel Hub Tightening 141 Wheel Installation 141 Wheel Nuts 141 Wheel Removal 140 Index 181
2. 120 121 Choke Lever 58 Cleaning p35 ah Sele 147 Clothing es ase eda 11 Consumer Product Safety 9 CVT 117 CVT System 116 117 Cylinder Head Torque 114 D Daytime Running Lights 143 Drive Chain 133 Drive Chain Slack 134 Drive Chain Slack Adjustment 135 Driving Downhill 85 Driving on Sidehill 84 Driving on Slippery Surfaces 89 Driving Over Obstacles 81 Driving Procedure 79 Driving Through Water 90 91 Driving Uphill 82 83 E Electronic Throttle Control 61 Emission Control Systems 93 Engine Start Button 59 Engine Stop Switch 58 Equipment Modifications 12 Exhaust Exposure to 15 Eye Protection 11 F Fuel Filtet ruere nae ek 109 Fuel Safety 15 Fuel 152 Fuel System 65 66 G Gas tsi flea tibet 43 65 Gasoline Handling 15 Gearcase Capacity 111 GIOVES pede bbe k oe Mes 11 H Handlebar Adjustment 138 Helmet ssi 10 59 Horn Button 41 l Instruction Operating 14 K Key 57 Kick Start L
3. b neyo 990606 VYaseds 654 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string mamma lt 130 Maintenance Toe Alignment 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measure ment on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment Repeat the measurement procedure on the other side of the vehicle If you discover improper alignment see your Polaris dealer for service 131 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 rear shock absorber springs are adjustable to increase or decrease spring tension Rotate the adjuster either clockwise or counter clockwise to make adjust ments 132 Maintenance Drive Chain Lubricate the drive chain with Polaris chain spray lube or an approved chain lube at the gen eral lubrication interval specified in the Periodic Maintenanc
4. Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first a Hours Calendar Miles Km age gt Wiring 100 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connec tors subjected to water mud etc E Clutches drive and driven 100 12M 1000 1600 Inspect clean replace worn parts E Front wheel bearings 100 12M 1000 1600 Inspect replace as needed Spark arrestor 300 36 M 3000 4800 Clean out 118 E Toe adjustment Inspect periodically adjust when 130 parts are replaced 101 Maintenance Lubrication Guide Item Lube Method Engine Oil Polaris Synthetic Youth Oil or Synthetic SAE 40 See page 104 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 110 Drive Chain Polaris Chain Lube or SAE 80 90 See page 133 gt Front Suspension A Arm Polaris All Season Premium Grease or grease conforming to NLGI No 2 Inspect tighten fasteners grease also after washing ATV or driving in water gt Perform these procedures more often for vehicles subjected to severe use 102 Maintenance Lubrication Guide Grease Points Grease Points 103 Maintenance Engine Oil Oil Recommendations Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart b
5. 19 Safety Safety Warnings Turning Improperly Turning 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 speeds 20 Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Safety Safety Warnings Improper Hill Climbing Operating on Steep Hills Improper hill climbing could cause loss of control Operating on excessively steep hills could cause or overturn Always follow proper procedures for an overturn Never operate on hills too steep for climbing hills as described in the owner s the ATV or for your abilities Never operate the manual See page 82 ATV on hills steeper than 15 degrees 21 Safety Safety Warnings Descending Hills Improperly Improperly descending 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 85 Always check the terrain carefully before descending a hill Shift your weight rearward Never travel down a hill at high speed e Avoid trav
6. WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law 168 Warranty HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Recommended Lubricants 1 Mixing oil brands or using non recommended oil
7. Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer 162 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with 5 amp charger Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer 163 Troubleshooting Engine Runs Irregularly Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fu
8. 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees NOTICE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 120 Maintenance Carburetor If the engine idle speed is not satisfactory and all other conditions are favorable the carbure tor can be adjusted 1 2 3 4 Start the engine Lock the parking brake Allow the engine to run for approximately five minutes Adjust the carburetor idle screw either in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclock wise will lower RPM 121 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 the consume
9. Out of fuel Turn the fuel valve to reserve refuel Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter Replace the filter Low battery voltage Recharge battery with 5 amp charger Mechanical failure See your Polaris dealer 160 Troubleshooting Engine Doesn t Turn Over Possible Cause Solution Low battery voltage Recharge battery with 5 amp charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 161 Troubleshooting Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs
10. Outlaw 50 08 12 2 3 mm 08 12 2 3 mm 125 Maintenance Brake Freeplay Front Brake Adjustment 1 Position the vehicle on a level surface 2 Elevate the front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground 3 While rotating the eft front wheel tighten the upper front brake adjuster nut on the right hand control 4 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 126 Front Brake Adjuster Nuts Maintenance Brake Freeplay Front Brake Adjustment 5 6 7 90 While rotating the right front wheel tighten the ower front brake adjuster nut on the right hand control When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn Verify that the right hand brake functions correctly Verify that brake lever freeplay is at specification See page 125 Carefully lower the vehicle to the ground 127 Maintenance Brake Freeplay Rear Brake Adjustment 1 Position the vehicle on a level surface 2 Elevate the rear of the vehicle by placing a suitable stand under the frame The rear tires should be slightly off the ground 3 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 4 When you begin to feel a slight drag in wheel rota tion loosen the wing nut one full turn 5 Verify that the left ha
11. See page 43 Release the air box cover clips and remove 4 NS the cover Remove the foam air filter Wash the foam Gasket filter in warm soapy water then rinse and let dry If the filter is damaged install a new S X foam filter Support Apply a commercially available foam filter lubricant to the foam filter Screen Clips 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 137 Maintenance Handlebar Adjustment A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death 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 handlebar to the desired height Be sure the handlebars do not hit the gas tank or any other part of the vehicle when turned fully to the left or right 3 Lightly tighten each bolt equally to prevent uneven gaps in the block Torque the bolts to 7 3 ft Ibs 10 Nm 138 Maintenance
12. Vary throttle positions Do not operate exercise extreme caution whenever han at sustained idle dling gasoline See page 15 5 Perform regular checks on fluid levels 2 Check the oil level Add the recom controls and areas outlined on the daily mended oil as needed Maintain the oil pre ride inspection checklist See page level in the proper range See page 105 72 3 Drive slowly at first Select an open 6 Perform the following maintenance at area that allows room to familiarize the end of the break in period yourself with operation and handling Item End of Break In Remarks See Page Engine oil change Perform break in oil change 106 Oil pre filter screen Clean filter with oil change 107 Transmission oil Perform break in oil change 110 Valve clearance See your dealer for inspection and adjustment 71 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 Remarks Page Brake system lever travel Ensure proper operation 125 129 Front suspension Inspect lubricate if necessary 102 Rear suspension Inspect lubricate if necessary 102 Steering Ensure free operation lubricate if necessary 130 132 Tires Check condition and pressure 139 Wheels fasteners I
13. adult start your ATV But before the is started for the first time you must do a Pre Ride Check In fact every time you want to ride you must have an adult help you check some things on your ATV before starting it Let s learn about these things now Make sure the throttle doesn t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close to the handlebar the ATV has a sticky throttle This means that something is wrong or broken and must be fixed before you can ride your ATV safely Never start the engine if you have a sticky throttle You could be seriously hurt if you ride with A a sticky throttle Have an adult or your Polaris dealer fix the throttle before you ride 47 Pre Ride Check Make sure the brakes don t stick Check the brake levers by squeezing them toward the handlebar and then letting go They should come right back to where they were before you squeezed If they go back slowly or stay close to the handlebar your ATV has sticky brakes They must be fixed before you can ride your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride A with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you ride Have an adult check to see if your ATV needs more gas Children must never add their own
14. after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 112 Maintenance Spark Plugs Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheat ing caused by use of an improper spark plug or incorrect carburetor throttle body adjust ments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Change 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclock wise to remove it 3 Reverse the procedure for spark plug installation Torque to 14 ft 16 19 Nm 113 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 If the vehicle tips or ov
15. after using the main supply Always return the valve to the ON position after refueling 66 Features and Controls Footwell Riser The removable footwell risers improve riding ergonomics and provide comfort for shorter operators An operator will also have better control of the ATV when both feet can remain firmly planted on either the footwells or the risers If the operator s legs are long enough to comfortably reach the footwells without the risers the risers can be removed 1 Remove the rubber caps covering the screw access holes Remove the screws and nuts securing the footwell riser to the footwell Remove the riser Reverse the procedure to reinstall the foot well riser for shorter operators 67 Features and Controls Kick Start Lever If the battery becomes too weak to start the Kick Start Lever engine use the kick start lever to start the engine until the battery is serviced 1 Position the vehicle on a level surface 2 Lock the parking brake 3 Fold out the kick start lever on the left side of the vehicle 4 Push the engine stop switch up to the ON position 5 Turn the key to ON 6 Place your foot on the kick start then thrust your heel downward to crank the engine 7 After the engine has started fold the kick start lever back into place 68 Features and Controls Kick Start Lever 8 Ifthe kick start lever is not installed remove the lever from the
16. black cable last Torque the battery terminal bolts to 3 5 ft Ibs 4 7 Nm 3 Install the mounting bracket and battery to the vehicle Tighten the three bolts 4 Verify that battery cables are properly routed 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 Recharge as needed to maintain a full charge 146 Maintenance Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle 147 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 with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medi
17. black cable last The battery in your Polaris ATV is a sealed battery The sealing strip cannot be removed Never add water to this type of battery Keep the battery terminals and connections free of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly 144 Battery Battery Removal 1 Remove the three bolts securing the battery mounting bracket to the vehicle Remove the mounting bracket and battery Disconnect the black negative battery cable first Disconnect the red positive battery cable last Loosen the two nuts securing the battery plate to the top of the battery Remove the plate Lift the battery out of the mounting bracket Mounting Bracket Bolts Maintenance 145 Maintenance Battery Battery Installation 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 1 Place the fully charged battery in the mounting bracket Reinstall the battery plate and tighten the two nuts securely to retain the battery in the mounting bracket 2 Connect and tighten the red cable first Connect and tighten the
18. it run in an enclosed area The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 15 Safety Safety Warnings Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 16 Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a serious injury in the event of an accident Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Safety Safety Warnings Carrying a Passenger Using Alcohol or Drugs Carrying a passenger greatly reduces the Operating the ATV after consuming alcohol or operator s ability to balance and control the ATV drugs could adversely affect operator judgment which may result in an accident or overturn reaction time balance and perception Never Never carry a passenger on this ATV consume al
19. loss of control resulting in SEVERE INJURY or DEATH 7175378 36 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 failure possible imbalance and excessive engine RPM which can result in serious injury or death 7174694 37 38 Youth Section 39 Know Your ATV PARENTS Polaris Youth ATVs are equipped with a speed control system to allow adults to limit the speed of the vehicle for the rider s skill and experience More information on speed limiting functions can be found beginning on page 122 These units are not designed for adult use Serious damage to the vehicle may occur if the maximum rider weight capacity is exceeded See the specifications section beginning on page 156 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know Your safety and the safety of others is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re 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 A means PAY ATTENTION becau
20. may cause engine damage We recommend the use of Polaris engine oil 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 169 Warranty EXPORTED VEHICLES EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BUL LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s war ranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military personnel on assignment out side the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs 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 was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris de
21. 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 Visit us at www polarisindustries com POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc Copyright 2008 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is expressly prohibited Printed in U S A 2009 Outlaw 50 ATV Owner s Manual P N 9921811 2 Welcome Dear Parents We believe your children should have the opportunity to enjoy The Way Out experience along with you We ve provided this owner s manual to assist you and your children in learn ing about safe operation and care of your new ATV A Polaris ATV is not a toy and can be hazardous to operate Make sure any child who will operate the ATV takes a training course before operating the ATV Make sure all operators understand and follow all of the instructions and warni
22. 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 begin ning on page 94 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 158 for the part numbers of Polaris products 1 Position the vehicle on a level surface Remove the fill plug View the oil level through the fill hole If the level is low add the recommended oil Reinstall the fill plug Drain Plug 5 110 Maintenance Transmission Oil Change 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 Ibs 19 Nm Add the recommended oil Maintain the oil level at the bottom of the fill plug hole threads Reinstall the fill plug Check for leaks Dispose of used oil properly ONS re Gearcase Capacity Outlaw 50 11 8 oz 350 ml 111 Maintenance Spark Plugs Refer to the specifications section beginning on page 156 for spark plug and gap specifica tions 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 The spark plug firing end condition should be read
23. sitting down Keep both hands on the handlebars and keep both feet on the footrests gt Always be alert and pay attention to where you re driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do gt Never follow another ATV too closely You need lots of time and space to stop your ATV gt Never tow or pull an object behind the ATV 52 Riding Rules gt Never ride alone An adult should always be watching you in case you need help Always drive within the sight of an adult gt Never ride on public trails gt Don t ride your ATV on roads or over railroad tracks Your ATV makes noise that will keep you from hearing cars trucks or trains that may be coming towards you gt Don t ride at night Your ATV doesn t have lights that are safe for driving in the dark gt Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them gt Never ride on frozen water You could get hurt or you could even die All ice can be dan gerous gt Ride your ATV only where you know it is safe to drive and where you have permission to drive Be careful of the things around you gt Always be a polite driver Don t drive through the flower garden or over the little trees you planted gt Always do your best to help take care of nature 53 54 Respect your ATV respect your environment and you will earn the respect o
24. than 10 hours gt General lubrication 50 3M 500 800 Lubricate all fittings pivots cables etc HE Valve clearance 50 3M 500 800 Check clearance see your dealer for adjustments Carburetor float bowl 50 6M 500 800 Drain bowl periodically and prior to storage Throttle cable ETC switch 50 6M 500 800 Inspect adjust lubricate replace if necessary Choke cable 50 6M 500 800 Inspect adjust lubricate replace if necessary 99 Maintenance Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first oo Hours Calendar Miles Km age E Carburetor air intake 50 6M 500 800 Check for proper sealing air leaks ducts flange E Drive belt 50 6M 500 800 See your Polaris dealer gt E Brake pad wear 50 6M 500 800 See your Polaris dealer HE Fuel system 100 12M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Fuel filter 100 12M 1000 1600 Change filter 109 gt Engine mounts 100 12M 1000 1600 Inspect Exhaust muffler pipe 100 12M 1000 1600 Inspect m Ignition timing 100 12M 1000 1600 Inspect gt Perform these procedures more often for vehicles subjected to severe use Emission Related Service Have an authorized Polaris dealer perform these services 100
25. the safe riding rules found on the next pages You or others around you could A be seriously hurt if you don t follow the safe riding rules 50 gt Always wear the right kind of clothing and safety gear when riding your ATV Helmet Your helmet is very important for safe riding A helmet can prevent a severe head injury Eye Protection Always wear shatterproof goggles or a helmet face shield and always keep them clean so you can see where you re driving Gloves Wear gloves to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from scrapes and scratches Clothing Make sure your clothing fits properly If it s too small it could keep you from moving easily when Riding Rules Long Sleeves you shift your weight If it s too big it could hang down and get caught in a moving part Wear long sleeves and long pants to protect your arms and legs 51 Riding Rules gt Always attach the tether strap to your right wrist and to the ATV before riding gt 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 gt Your ATV is made for one person Never carry a passenger A passenger will make the ATV harder to drive You may lose control and hurt yourself and your passenger gt Always drive your ATV while
26. under seat storage area 9 Remove the plug from the kick start access hole on the left side of the vehicle Tip Store the plug in a secure location Always reinstall the access hole plug whenever the kick start lever is removed from the vehicle 10 Install the kick start lever through the access hole 69 Operation AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death 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 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 a new engine will result in more efficient performance and longer life for the engine Per form the following procedures carefully NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 70 Break in Period Operation 1 Full the fuel tank with gasoline Always 4
27. 1 888 704 5290 Canada 1 204 925 7100 171 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 the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance 172 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 LIM ITED WARRANTY ARE THE ONLY
28. Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power The addition of certain accessories may change the handling characteristics of the ATV Use only Polaris approved accessories and familiarize yourself with their function and effect on the ATV 12 Safety Safety Warnings AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Be sure to read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your child s safety Be sure to explain to your young driver that the hazards outlined in this section of the owner s manual MUST be avoided at all times See the RIDING RULES section and the OPERATION section of the owner s manual for proper operating procedures Operator Restrictions Age Restrictions This vehicle is for recreational use by young operators under adult supervision ONLY Operation is prohibited for anyone under 6 years of age AN Safety Safety Warnings Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operat
29. NING Improper ATV use can result in SEVERE INJURY OR DEATH Always use an approved helmet and protective gear Never use on public roads Never carry passengers Never use with drugs or alcohol NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 33 Safety Safety Labels and Locations Age Warning WARNING Operation of this ATV by children under the age of 6 increases the risk of severe injury or death Adult supervision required for children under age 16 NEVER permit children under age 6 to operate this ATV 7175372 34 Safety Labels and Locations Tire Pressure Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 2 0 psi 13 8 kPa Rear 2 0 psi 13 8 kPa e Maximum Weight Capacity 90 Ibs 41 kg 7176085 35 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a
30. OUTLAW 50 2009 Owner s Manual for Maintenance and Safety POLARIS The Way Out Read this manual carefully It contains important safety information Adult supervision is required at all times Operation is prohibited for those under 6 years of age AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control For your nearest Polaris dealer call 1 800 POLARIS PELARIS or visit www polarisindustries com The Way Out Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921811 Rev 02 Printed in U S A AWARNING The engine exhaust from this product contains chemicals known to 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
31. REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing com petition This limited warranty also does not cover physical damage corrosion or defects caused by fire explo sions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris War ranty Department at 1 888 704 5290 173 Maintenance Log Present this section of your manual to your dealer each
32. Tires AWARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death 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 139 Maintenance Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less 1 8 3 mm v 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 suitable stand under the footrest frame 4 Remove the wheel bolts and remove the wheel 140 Maintenance Wheel Installation 1 2 3 4 Lock the parking brake 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 Install the wheel bolts and finger tighten them Lower the vehicle to the ground Securely tighten the bolts to 22 ft 165 30 Nm 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 141 Mainte
33. Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be dis played on the label 10 Long Helmet Sleeves Protection gloves Long Pants 051039 0006 31 Safety Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of strong over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with knee pads and a jersey with shoulder pads provide the best protection Safety Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes
34. Warnings 13 31 Handling Gasoline 15 Hot Exhaust Systems 31 Improper Cargo Loading 29 Improper Hill Climbing 21 Improper Tire Maintenance 26 Improper Vehicle Modifications 27 Jumps and Stunts 20 Operating a Damaged ATV 30 Operating at Excessive Speeds 19 Operating in Unfamiliar Terrain 26 Operating on Frozen Bodies of Wa e Ran As 30 Operating on Pavement 18 Operating on Public Roads 18 Operating on Slippery Terrain 25 Operating on Steep Hills 21 Operating Over Obstacles 27 Operating Through Deep Water 28 180 Safety Warnings 13 31 Operating Without Instruction 14 Physical Control of the ATV 19 Physical Skills 30 Protective Apparel 16 Skidding or Sliding 27 Stalling While Climbing a Hill 24 Turning Improperly 20 Unauthorized Use of the ATV 31 Using Alcohol or Drugs 17 Safety Words and Symbols 6 Seat Latch yin ie 43 Severe Uses 95 Shock Spring Adjustment 132 Sidehilling Signal words Spark Arrestor 118 1 8 Spark Plug Change 113 Spark 112 113 Specifications 156 157 S Speed Control System 122 123 Start 59 Starting the 76 77 Steering Inspection 132 Stop
35. aintenance Chart your dealer for adjustments Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Drive chain Daily Inspect daily adjust and lubricate 133 if needed CVT housing if equipped Weekly Drain water as needed check 117 often if operating in wet conditions Break in Maintenance After first 10 hours of operation Perform break in maintenance 70 gt E Brake lever travel brake 10 Monthly 100 160 Inspect regularly 125 freeplay 129 E Spark plug 10 Monthly 100 160 Clean check condition adjust 112 gap replace as needed Idle speed 10 Monthly 100 160 Check adjust as needed 121 Choke 10 Monthly 100 160 Check for proper operation see gt Perform these procedures more often for vehicles subjected to severe use Emission Related Service Have an authorized Polaris dealer perform these services 98 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first 295 Hours Calendar Miles Km age Battery 20 Monthly 200 320 Check terminals clean test 144 gt Engine oil change 30 6M 300 480 Drain and change the oil 106 gt Transmission oil 40 12M 400 640 Drain and change the oil 110 gt Oil pre filter screen 40 12M 400 640 Clean filter at every oil change 107 clean annually if ATV is operated less
36. ake allowing the ATV to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the ATV from the uphill side keeping body weight uphill 7 Restart the engine 8 Squeeze the rear brake lever 9 Release the parking brake and drive slowly controlling speed with the rear brake until the ATV is on more level ground 87 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 illus tration 4 Turn the fuel valve off 88 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 2 3 Do not operate on excessively rough slippery or loose terrain Slow down when entering slippery areas Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Never apply the brakes during Sideways Turn in direction a skid Correct a skid by skid of skid turning the handlebars inthe c PA A Y o direction of the skid and gt l Ren KS shifting your body weight C C YW s c forward 89 Operation Driving Through Water Your ATV can safely operat
37. aler You must show the dealer photo identification from the country of the sell ing dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair 170 Warranty EXPORTED VEHICLES How to Get Service If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present documentation of your move to Polaris Industries in order to continue your warranty coverage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the proce dure 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 purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States
38. anges Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving The friction will help dry out the pads 28 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 does not have brakes or steering The object may overturn or collide with other objects Never exceed the stated load capacity for this ATV 29 Safety Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water 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 30 Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control Safety Warnings Hot Exhaust Systems Exhaust system components are very hot durin
39. by Full Choke pushing the choke lever all the way to the left Do not use the choke when starting a warm engine Tip The choke is fully on when the lever is pushed completely to the left The choke is off when the lever is pushed completely to the right The choke can be adjusted gradually depending on how much choke is needed for starting 76 Operation Starting the Engine 6 Push the engine stop switch up to the ON position 7 Turn the ignition key to ON 8 Squeeze the rear brake lever and press the start button The rear brake lever must be engaged for the engine to start 9 Do not press the throttle while starting the engine 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 five seconds then activate for another five seconds Repeat until the engine starts 10 If the engine slows or stops position the choke lever half way to allow proper engine warm up Vary the RPM slightly with the throttle to aid in warm up 11 When the engine idles smoothly push the choke lever completely to the right 77 Operation Stopping the Engine 1 Release the throttle completely 2 Apply the brakes until the vehicle stops moving 3 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 the ATV 4 Lock the parking bra
40. cohol or drugs before or while operating an ATV 17 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 designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops 18 Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Safety Safety Warnings Operating at Excessive Speeds Physical Control of the ATV Operating the ATV at excessive speeds Removing a hand from the handlebars or feet increases the operator s risk of losing control from the footrests during operation can reduce Always operate at a speed that s appropriate for your ability to control the vehicle or cause loss of the terrain the visibility and operating conditions balance and ejection from the ATV If the and your experience operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests
41. dling This war ranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used 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 war ranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery mate rial corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control 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 or replace ment of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WAR RANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSE QUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHER WISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 167 Warranty
42. e Chart beginning on page 94 Lubricate more often under severe use such as in dirty or wet conditions See page 158 for the part numbers of Polaris products NOTICE Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t use a high pressure washer or gasoline to clean the drive chain Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive components Always make sure the slack is within the stated specifications 133 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 The chain should have 1 4 1 2 6 12 mm deflection If the chain needs adjustment use the procedure on page 135 1 4 1 2 6 12 mm Deflection 134 Drive Chain Slack Adjustment 1 Loosen the four rear housing mount bolts Loosen the chain adjuster lock nut Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection Tighten the chain adjuster lock nut to 18 ft Ibs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid breaking the stud Tighten the four rear housing mount bolts to 43 ft Ibs 60 Nm Maintenance 50 mig Chain Adjuster Bolts 135 Maintenance Air Filter 1 2 3 136 Remove the seat
43. e Periodic Main tenance Chart beginning on page 94 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 ventilated 4 Cover the vehicle with an appropriate cover Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 154 Maintenance Transporting the ATV Follow these procedures when transporting the ATV Stop the engine Place the transmission in gear Lock the parking brake Secure the fuel cap oil cap and seat Turn the fuel valve off Always 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 the unit ON Be Ge Accessories Polaris has a wide range of accessories available for your ATV Please see your Polaris dealer 155 Specifications Outlaw 50 Rider Capacity 1 Rider Maximum Weight Capacity 90 Ibs 41 kg Displacement 49cc Cooling Air Cooled Engine type 4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 2 gallons 4 5 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automatic CVT Fi
44. e the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the ATV RiderCourses offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org 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 14 Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions e Never allow a child to refuel or handle gasoline Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Turn the fuel valve off whenever the ATV is stored or parked See page 66 Safety Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let
45. e 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 Ifcrossing a stream choose a crossing where both banks have gradual inclines 3 Avoid operating through deep or fast flowing Maximum Water Depth water 90 Operation Driving Through Water 4 After driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes may be ineffective NOTICE Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper than the footrest level As soon as possible perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 94 Engine oil gearcase oil front and rear gearcases if equipped and all grease fittings need special attention If the vehicle tips or overturns in water or 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 114 then see your dealer for service at the first opportunity 91 Emission Control Systems Noise Emis
46. efore starting the engine When the engine starts gradually return the choke lever to the OFF position as the engine warms up and runs smoothly 58 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 Turn the key to the ON position 3 Lock the parking brake 4 Push the engine stop switch up to the ON position 5 Press the start button 59 Features and Controls Throttle Controls A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation 60 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
47. eginning on page 94 Oil may need to be changed more frequently if Polaris oil is not used Do not use automotive oil See page 158 for the part numbers of Polaris products Under These Operating Conditions Use This Recommended Oil Outside air temperature is above 32 F 0 C Polaris Synthetic Youth Oil or Synthetic SAE40 Outside air temperature is below 32 0 Semi Synthetic 20W 40 NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands 104 Engine Oil Check Maintain the oil level within the safe range on the dipstick Do not overfill 1 2 3 4 Tip Position the vehicle on a level surface Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immedi ately Add the recommended oil as needed Reinstall the dipstick Maintenance Safe Range Add Oil Full 105 Maintenance Engine Oil Change 1 Position the vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Ho
48. el filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer 164 Engine Stops or Loses Power Troubleshooting Possible Cause Solution Out of fuel Turn the fuel valve to reserve refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery with 5 amp charger Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer 165 Warranty LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in materia
49. eling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible 22 Safety Warnings Crossing Hillsides 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 hillside is unavoidable always follow proper procedures as described in the owner s manual See page 84 Never attempt 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 86 Safety WO Wy O 5 XS KLE AY 23 Safety Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn Always maintain a steady speed when climbing a hill If all forward speed is lost If you lose all forward speed Keep your weight uphill Apply the front brakes gradually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If the ATV begins rolling downhill Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the front brake slowly When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to either side if pointed straig
50. embers This training 1s included in the purchase price of your ATV Polaris strongly encourages you and your age eligible family members who will be riding the ATV to take the ATV RiderCourse In addition you were provided with printed material and a video or DVD that instructs operators on safe operating procedures You should review this information with your child on a regular basis Do not allow other children to ride this ATV unless they have read the manual seen the instructional video or DVD and taken and completed an approved ATV safety training course such as the ATV RiderCourse Safety Training If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchas ers of a used Polaris ATV will be charged for this training Safety FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Safety Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of
51. emove 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 maintain a full charge 151 Maintenance Storage Stabilize the Fuel Polaris Carbon Clean is a fuel stabilizer and fuel system dryer It cleans the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stop the engine Turn the fuel valve off 6 Drain the carburetor bowl 152 Maintenance Storage Engine Oil Change the oil See page 106 Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 94 Transmission Oil Engine Oil e Brake Fluid 153 Maintenance Storage Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in th
52. erturns in water deeper than the footrest level or if the engine stops during or after operating in water restarting WILL result in serious engine damage Trans port 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 proce dure will allow short term operation only to drive the ATV to a trailer or towing vehicle 1 Move the ATV to dry land or at the very least to water below the footrests 2 Turn the fuel valve off 3 Check the air box for any water and dry it if water is present 4 Remove the spark plug 114 Maintenance Vehicle Immersion 5 6 Attempt to start the engine If necessary repeat the drying Take the ATV to your dealer for service as soon as possible If water has been ingested into the transmission follow the Loosen the carburetor drain screw Turn the engine over several times using the electric start Dry the spark plug and reinstall it or replace it with a new plug Tighten the carburetor drain screw Turn the fuel valve on procedure whether you succeed in starting it or not Drain Screw procedure on page 117 for drying the CVT 115 Maintenance Constant Variable Transmission CVT System AWARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the CVT system Doing so ma
53. ever 42 68 69 86 L Lamp Replacement Daytime Running Lights 143 Lighter eee aed 142 Eights bed Whe 64 Lights Daytime Running 143 Lubrication Guide 102 103 M Main Key Switch 57 Maintenance Chart 94 101 Making 80 12 Meme 104 Oil Change Engine 106 108 Oil Change Transmission 111 Oil Check Engine 105 Oil Check Transmission 110 Oil Lee eee Y 104 Operator Restrictions 13 Parking on a Hill or Incline 88 Periodic Maintenance Chart 94 101 Polaris Products 158 Polishing eee ed eres 150 Pre Ride Inspection 72 73 R Restrictions 13 Riding 10 11 S Safe Operation Practices 74 75 Safety Labels Age Warning 34 Clutch Cover Warning 37 Discretionary Warning 32 No Passenger Warning 36 Operation Warning 33 Tire Pressure Warning 35 Safety Labels and Locations 32 37 Safety Training 8 9 Safety Warnings 13 31 Age Restrictions 13 Carrying a Passenger 17 Crossing Hillsides 23 Descending Hills Improperly 22 Exposure to Exhaust 15 Failure to Inspect 16 179 Index S Safety
54. f everyone Enjoy riding your new Polaris ATV Adult Section 55 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 keys The igni tion switch must be replaced if all keys are lost Frame Identification Number Vehicle Model Number Frame Identification Number Engine Serial Number Key Number on the key 56 Engine Serial Number 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 57 Features and Controls Engine Stop Switch The engine will not start or run when the stop switch is down in the OFF position Its pur pose 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 off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Horn Stop Switch Start Button Choke Lever Use the choke to start a cold engine Push the choke lever to the left b
55. g and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Always inspect the underside of the ATV after driving through tall grass weeds brush and other tall ground cover Promptly remove any grass or debris clinging to the vehicle Safety Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 31 Safety Safety Labels and Locations Warning labels 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 becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label 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 32 Safety Labels and Locations Operation Warning WAR
56. 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 Pre Ride Check v Ifyou used the storage area under the seat make sure the seat is locked in place Have an adult check the engine oil level when the engine is cold The engine is very hot after it has been running and it can burn your skin if you touch it Children must never check the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks This last check is done with the engine running You must check to make sure that all three ways to stop the engine of your ATV are working the way they should Do you remember what they are If you can t remember the three ways to stop the engine go back to page 46 and review Then have an adult help you start the engine Practice stop ping the engine all three ways 49 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 gt The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always drive safely Let s learn how to ride Always follow
57. ht uphill Turn the ATV around and remount following the procedure described in the Owner s Manual See page 86 24 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 and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain 25 Safety Safety Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 26 Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or 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 Safety Warnings Improper Vehicle Modifications Improper installation of accessories or modification of the ATV may cause changes in handling which could cause loss of contr
58. ine case near the clutch box The installation of devices that effectively increase exhaust emissions beyond their legal lim its will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with the EMC requirements of European directives 97 24 EC and 2004 108 EC 93 Maintenance Periodic Maintenance Chart To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Maintenance intervals in the following charts are 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 174 94 Maintenance Periodic Maintenance Chart Inspect clean lubricate adjust and replace parts as necessary When inspection 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 mud water or sand e Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short t
59. ing in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operating the ATV Locked 63 Features and Controls Brakes Parking Brake The CVT system is always in forward gear Using the throttle to warm the engine will cause the vehicle to move forward if the parking brake is not locked Always lock the parking brake before starting the engine Always lock the parking brake whenever the vehicle is left unattended Lights Polaris Youth ATVs are not equipped with lights that are designed for driving in the dark Do not operate this ATV after dark Use caution and drive at reduced speeds in conditions of reduced visibility This ATV is designed for off road use only Do not operate this ATV on streets or highways 64 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 156 for fuel tank capacity Features and Controls 65 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 The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill the gas tank as soon as pos sible
60. ke 5 To avoid draining the battery always turn the key to the OFF position when the engine is not running 78 Operation Driving Procedure 1 2 3 Wear a helmet and eye protection Sit upright with both feet on the footrests and both hands on the handlebars Lock the parking brake Start the engine and allow it to warm up Check your surroundings and determine your path of travel Slowly squeeze and release the left brake lever to unlock the parking brake Slowly press the throttle with your right thumb and begin driving Drive slowly at first Practice turning and using the throttle and brakes on level surfaces 79 Operation Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly Practice making turns at slow speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 80 Driving Over Obstacles Follow these precautions when operating ove
61. ke the vehicle to your dealer for service as soon as possible NOTICE Exposure to salt water will cause corrosion to metal components If your vehicle is operated in salt water areas rinse it off frequently with fresh water 117 Maintenance Spark Arrestor To remove accumulated carbon clean the spark arrestor at the intervals recommended in the Periodic Maintenance Chart beginning on page 94 A 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 e Wear eye protection and gloves Never run the engine an enclosed area Exhaust contains poisonous carbon monoxide gas 118 Maintenance Spark Arrestor 1 Remove the three bolts and remove the arrestor from the end of the muffler Bolts 2 Use anon synthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage Arrestor Replace the arrestor if damage is found Screen 4 Reinstall the arrestor 5 Torque the bolts to 7 ft Ibs 9 5 Nm 119 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 Above 6000 feet
62. l or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGIS TERED 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 166 Warranty WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper han
63. nal Drive Chain Front Suspension Single control arm with 3 7 6 cm of travel Rear Suspension Spring over shock with 3 7 6 cm of travel 156 Specifications Outlaw 50 Front Rear Brakes Drum Parking Brake Mechanical Lock Front Tires 16 x 6 5 7 2 psi 13 8 kPa Rear Tires 16 x 8 7 2 psi 13 8 kPa Dry Weight 210 Ibs 95 3 kg Length Width Height 48 122 cm 31 5 80 cm 28 71 cm Wheel Base 33 84 cm Ground Clearance 4 10 cm Brake Light Standard Daytime Running Lights Standard 157 Polaris Products Part Number Description Engine Lubricant 2876248 Synthetic Youth Oil qt 95 1 2876249 Synthetic Youth Oil gal 3 8 1 2872175 Semi Synthetic 20W 40 Oil qt 95 1 2872176 Semi Synthetic 20W 40 Oil gal 3 8 I 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 1 2872348 Chain Lube Aerosol 158 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease 3 0z 89 ml 2871423 All Season Premium Grease 14 02 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus 159 Troubleshooting See your Polaris dealer if you re unable to identify solutions using the following charts Engine Turns Over Fails to Start Possible Cause Solution
64. nance 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 142 Maintenance Daytime Running Lights Lamp Replacement If the daytime running lights do not operate replace the lamps Polaris recommends that you install replacement lamps obtained from your authorized Polaris dealer 1 Disconnect the lights from the harness 2 Remove the rubber cover from the back of the light assembly 3 Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out Install the new lamp Make sure the filament is horizontal Reinstall the lamp retainer Press the retainer inward and turn it clockwise about 1 4 turn 6 Start the engine to make sure the lights come on If the lights do not operate see your Polaris dealer for service 7 Reinstall the rubber cover and reconnect the lights to the harness Dose 143 Maintenance Battery A 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
65. nd brake functions correctly 6 Verify that brake lever freeplay is at specification See page 125 7 Carefully lower the vehicle to the ground 128 FT lle Rear Brake Wing Nut Maintenance Brake Lever Travel Check brake lever travel at the intervals recommended in the Periodic Maintenance Chart beginning on page 94 When freeplay 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 table below Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting Measure Lever Travel Component Total Lever Travel Front brake lever 1 3 4 45 mm Rear brake lever 2 1 2 65 mm 129 Maintenance Toe Alignment Use the following procedure to check the toe align ment of the vehicle The recommended toe alignment Stand 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 String adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer 1 Position the vehicle on a level surface 2 Place the handlebars in a straight ahead position 0 0 JIE 2200 00 S
66. ng your new Polaris ATV are ae tte Wie eet ahead Know Your ATV Pre Ride Check Table of Contents Adult Section 55 Vehicle ID Numbers 56 Features and Controls 57 70 Emission Control lt 92 Maintenance 94 Specifications 156 Polaris Products 158 Troubleshooting 160 Warranty 166 Maintenance Log 174 178 Introduction Safety Words and Symbols The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and symbols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage 6 Q The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard Introduction A WARNING Failure to follow the warnings and safety precautions contained in this manual can result in severe inj
67. ngs contained in this owner manual Help them also learn to show respect for our environment and for the rights of others while operating the ATV Never allow a child under the age of 16 to operate an ATV without adult supervision Chil dren differ in skills physical abilities and judgement Some children may not be able to oper ate an ATV safely Permit continued use only if you determine that your child has the ability and maturity to operate the ATV safely The preventive maintenance program outlined in this manual is designed to ensure that all critical components on your child s ATV are thoroughly inspected at specific intervals Fol low all of the instructions and recommendations in this manual Welcome Dear Children Before you ride your new Polaris ATV there are some important things that you need to know You must learn how to keep yourself and those around you safe while you re riding Your parents and Polaris want you to enjoy riding your new and that s why you need to read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others is the most important thing to think about at all times Never drive your ATV alone Always make sure an adult is watching you when you ride Drive safely and enjoy ridi
68. nspect ensure fastener tightness check that 141 141 axle nuts are secured by cotter pins Fuel and oil Check and fill as needed 15 65 72 Pre Ride Inspection Operation Pre Ride Checklist Item Remarks Page Throttle Check for proper operation 47 60 61 Engine stop switch Check for proper function 58 Daytime running lights if equipped Check for proper operation 143 Brakelight Check for proper operation 142 Air filter pre filter Inspect clean or replace 136 Drive chain Check condition and slack refer to drive 133 chain adjustment Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any damaged compo nents loose fasteners Riding gear Wear helmet goggles protective clothing 10 73 Operation Safe Operation Practices 1 74 Complete the recommended safety training before operating this vehicle See page 8 Do not allow anyone under 6 years of age to operate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Never exceed the maximum weight capacity of the vehicle When determin ing the weight you are adding to the vehicle include the weigh
69. ol or an accident Never modify the ATV through improper installation or use of accessories All parts and accessories added to the 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 See your authorized Polaris ATV dealer for more information Safety Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding 27 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 footrests Travel slowly Balance your weight carefully Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle ch
70. r obstacles 1 2 Always check for obstacles before operating in a new area Look ahead and learn to read the ter rain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visi ble Never attempt to operate over large obstacles such as rocks or fallen trees Operation 81 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 fol low these precautions 1 2 3 82 Drive straight uphill Avoid steep hills 15 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces 15 Maximum 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 or another vehicle or person could be on the other side of the hill 9 Remain alert and be prepared to take emergency action This may include quick dis mounting of the vehicle 83 Operation Driving on a Sidehill Sidehilling Driving on a
71. r s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable throttle limiting screw Speed limiting devices may be adjusted removed only by consumers when they determine that their child is capable of han dling the additional speed Per ANSI SVIA 1 2001 sec 6 2 the unrestricted top speed is less than 15 MPH for the 50cc models and less than 30 MPH for the 90cc models 122 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 Maintenance 123 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 limit 124 Nut 1 16 1 8 1 5 3 2 mm Check measure the freeplay of the front and rear brakes at the intervals rec ommended in the Periodic Maintenance Chart beginning on page 94 If the free play isn t at specification adjust the freeplay as outlined on the following pages Maintenance Measure Freeplay Brake Freeplay Specifications Model Front Brake Rear Brake
72. rip cold weather operation 95 Maintenance Periodic Maintenance Chart AWARNING Improperly performing the procedures marked with a W could 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 gt Perform these operations more often under severe use such as in dirty or wet condi tions to purge water or dirt contamination from grease fittings and other critical components E Enmission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions Dealer service item 96 Periodic Maintenance Chart Maintenance Item Maintenance Interval Remarks whichever comes first See Hours Calendar Miles Km Page Steering Daily Check each day before operating 72 Front suspension Se a eee Chea Rear suspension Daily list Tires Daily Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily Engine oil level Daily E Air filter pre filter amp main Daily Inspect clean often replace as 136 element needed Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric 142 grease if replacing 143 97 Maintenance Periodic M
73. se you could die or be seriously injured if you don t follow the instructions 40 Know Your ATV Before you have an adult start the engine for you for the first time let s learn about the con trols on your new ATV 1 2 3 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 Horn Button Press the horn button to sound the horn Throttle Control Press the throttle lever with your thumb when you want the ATV to go forward Always make sure the throttle control does not stick before you drive your ATV Read more about it on page 47 2 Horn Button JOENOINE Stop Switch 3 Throttle Control 41 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 4 Kick Start Lever 42 Know Your ATV 5 Gas Cap The gas cap has to be taken 5 Gas C off when an adult puts gas in your ATV Never take the gas cap off Always a 6 Seat Latch make sure it s tightly closed Always have an adult put gas in your A ATV Never try to do it yourself 6 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the seat To replace the seat se
74. 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 into the hill transferring your upper body weight uphill while keeping your feet on the footrests 3 Ifthe vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 84 Operation Driving Downhill When driving downhill follow these precautions 1 2 3 Avoid steep hills 15 maximum Shift body weight uphill Transfer your weight to the rear of the vehicle Drive straight downhill Slow down Excessive speed when traveling downhill can cause loss of control Apply the front and rear brakes at the same time and very slightly to aid in slowing 85 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 Shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 86 Operation Turning Around on a Hill 4 Staying uphill of the ATV turn the handle bars full left 5 While holding the brake release the park ing brake lock and slowly release the br
75. sion 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 require ments Operation on 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 arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 1 c Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system 92 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 main tained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or eng
76. t it in place and push down on the seat above the latch Always make sure the seat is locked in place before riding 43 Know Your ATV 7 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 could lose control of the ATV and A be seriously injured Always take your thumb off the throttle lever when you squeeze the brake levers 7 Rear Brakes 7 Front Brakes 44 Know Your ATV 8 Ignition Switch The ignition switch key 8 Ignition Switch must be turned on before pushing the start button You can also use this key to turn off 9 Tether Switch the engine 9 Tether Strap and Switch The tether strap must always be attached snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never ride without the tether strap attached to your right wrist and to your ATV Be careful not A to let the cord get tangled around the handlebars or any part of your body 45 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 Pre Ride Check We re almost ready to have an
77. t of the opera tor accessories loads on the racks if equipped and the load on the trailer tongue if equipped The combined weight of these items must not exceed the maximum weight capacity Safe Operation Practices 7 Drive in a manner appropriate for your skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the han dlebars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Operation Never operate a damaged ATV After any overturn or accident have a quali fied service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust system com ponents Always keep combustible materials away from the exhaust sys tem Always remove the ignition key when the vehicle is not in use to prevent unau thorized use 75 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 Lock the parking brake Turn the fuel valve on Sit on the vehicle Attach the tether strap to the ATV and to your wrist 5 Ifthe engine is cold use full choke
78. t oil can cause burns to skin Do not allow hot oil to contact skin 106 Maintenance Engine Oil Change 5 6 7 Place a drain pan under the engine crankcase Remove the pre filter plug Allow the oil to drain completely Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry Clean the pre filter plug Install a new sealing washer on the plug The sealing surfaces on the plug and crankcase should be clean and free of burrs nicks or scratches Reassemble the pre filter screen and spring to the pre filter plug 107 Maintenance Engine Oil Change 10 Reinstall the pre filter drain plug Torque to 11 ft Ibs 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 156 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the engine and inspect for leaks 15 Check the oil level Add oil as needed to bring the level to the upper mark on the dip stick 16 Dispose of used oil properly 108 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 94 Do not attempt to clean the fuel filter 109 Maintenance Transmission Oil Check The gearcase fill plug is located on the
79. the risk of a frozen or stuck throttle If the throttle gt cable should stick in an open position when the Throttle operator releases the throttle lever the engine will Lever stop and power to the rear wheels will cease WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the ETC system or replace it with any after market throttle mechanism Always ensure that the throttle cable is installed and properly routed to the throttle control 61 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 Always apply both brakes at the same time Rear Brakes Front Brakes 62 Features and Controls Brakes Parking Brake 1 Squeeze the left brake lever Not Locked 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 automatically WARNING Operating the ATV while the parking brake is engaged could cause an accident result
80. time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 10 Hours Break in 40 Hours 50 Hours 80 Hours 174 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours 175 Maintenance Log DATE SERVICE TECHNICIAN SERVICE PERFORMED COMMENTS INTERVAL 176 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 177 Index A 155 Age Restrictions 13 Air Filter 136 137 Axle and Wheel Nuts 141 B 144 146 Installation Connections 146 Removal 145 Storage 146 151 Boots grits Pode scott he 11 Brake Adjustment Front 126 127 Brake Adjustment Rear 128 Brake Freeplay 125 128 Brake Freeplay Specifications 125 Brake Lever Travel 129 Brake Levers 44 Brake Parking 63 64 Brakes ciation dancer hase 62 64 Break in Period 70 71 178 Camber and Caster 132
81. um to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 148 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 Cab and body panels e Radiator Labels and decals Transmission seals Electrical components and wiring Brakes If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system 149 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 e the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 150 Maintenance Storage Exterior Make necessary repairs and clean the vehicle as recommended See page 147 Battery Storage R
82. ury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all Always follow the age guidelines for your safety warnings precautions and operating vehicle Y 12 90cc models are designed for procedures before operating a Polaris ATV children not less than 12 years of age and Y 6 Keep this manual with the ATV 50cc models are designed for children not less Never operate an ATV without proper than 6 years of age No child under the age of instruction Take a training course Purchasers 16 should ride any ATV designed and sold for of a new Polaris ATV and their eligible family an adult members are entitled to take the ATV Never permit a guest to operate the ATV RiderCourses Contact ATV Enrollment unless the guest has read this manual and all Express at 800 887 2887 or visit product labels and has completed a certified www atvsafety org for information on safety training course enrollment in the ATV RiderCourses Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family m
83. y reduce its strength so that a failure may occur at a high speed The CVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe 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 it in any other product Always make sure the CVT housing is securely in place during operation 116 Maintenance Constant Variable Transmission CVT System CVT Drying There may be some instances when water is accidently ingested into the CVT system Use the following instructions to dry it out before operating The drain plug is located on the bot tom of the CVT cover 1 Remove the drain plug Allow the water to drain Reinstall the drain plug 2 Start the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed 4 Test for belt slippage If the belt slips repeat the process 5 Ta

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