2002 Polaris Universal Youth ATV Owners Manual
2002 Polaris Universal Youth ATV Manual
2002 Polaris Universal Youth ATV manual content summary:
- 2002 Polaris Universal Youth ATV | Owners Manual - Page 1
- 2002 Polaris Universal Youth ATV | Owners Manual - Page 2
WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 3
Indicates a potential hazard which could result in severe injury or death. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 4
PARENTS: Review the information in this manual with any child who may be operating the ATV. It is up to you to teach your child the proper and safe way to ride - 2002 Polaris Universal Youth ATV | Owners Manual - Page 5
ii - 2002 Polaris Universal Youth ATV | Owners Manual - Page 6
vehicles (ATVs). It is designed to provide superior riding comfort, enjoyment, and safety. This manual is furnished to ensure that the operator and parents are aware of safe operating procedures. It also dealers have the knowledge and facilities to provide you with the best service possible. iii - 2002 Polaris Universal Youth ATV | Owners Manual - Page 7
maintenance program is designed to ensure that all critical components on this ATV are thoroughly inspected at various intervals. All information in this manual is based upon the latest product data and specifications available at the time of printing. Polaris Industries Inc. reserves the right to - 2002 Polaris Universal Youth ATV | Owners Manual - Page 8
. Failure to follow the warnings contained in this manual can result in SERIOUS INJURY or DEATH. • Read this manual and all labels carefully and follow the operating procedures described. • Never operate an ATV without proper instruction. Take a training course. Riders should receive training from - 2002 Polaris Universal Youth ATV | Owners Manual - Page 9
ride an ATV designed and sold for an adult. • Do not allow other children to ride this ATV unless they have read the manual, seen the instructional video and taken and passed a Polaris approved riding skill test. • Always avoid operating an ATV on any paved surfaces, including sidewalks, driveways - 2002 Polaris Universal Youth ATV | Owners Manual - Page 10
time you use it to make sure it is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. • Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. • Always go slowly and be extra - 2002 Polaris Universal Youth ATV | Owners Manual - Page 11
sharply to one side. Go straight down the hill where possible. • Always follow proper procedures for crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV. Never attempt to turn the ATV around - 2002 Polaris Universal Youth ATV | Owners Manual - Page 12
on the uphill side or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in this manual. • Always check for obstacles before operating in a new area. Never attempt to operate over large obstacles, such as large rocks or fallen trees. Always - 2002 Polaris Universal Youth ATV | Owners Manual - Page 13
Never exceed the stated load capacity for an ATV. Cargo should be properly distributed and securely attached. Reduce speed and follow instructions in this manual for carrying cargo. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission - 2002 Polaris Universal Youth ATV | Owners Manual - Page 14
made to the ATV which increase its speed or power. We also advise you to strictly follow the recommended maintenance program outlined in this manual. This preventive maintenance program is designed to ensure that all critical components on the ATV are thoroughly inspected by your dealer at various - 2002 Polaris Universal Youth ATV | Owners Manual - Page 15
TABLE OF CONTENTS RIDER'S SECTION ...R-1 - R-20 UNDERSTANDING WARNINGS ...1 - 4 GENERAL SAFETY AND DESCRIPTION OF LABELS ...5-19 DAILY PRE-RIDE CHECK ...20-21 OPERATION WARNINGS ...22-46 VEHICLE IDENTIFICATION NUMBERS ...47-48 CONTROL AND PARTS FUNCTIONS ...49-69 STARTING THE ENGINE ...70-71 RIDING - 2002 Polaris Universal Youth ATV | Owners Manual - Page 16
TABLE OF CONTENTS PVT SYSTEM OPERATION ...104-105 BATTERY ...106-111 NOISE EMISSION CONTROL SYSTEM REGULATION ...112-114 MAINTENANCE ...115-163 SPECIFICATIONS ...164-170 WIRING DIAGRAMS ...171-172 TROUBLE SHOOTING ...173-174 WARRANTY ...175-180 INDEX ...- xiii - 2002 Polaris Universal Youth ATV | Owners Manual - Page 17
RIDER'S SECTION R--1 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 18
to the rider's skill and experience. More information on speed limiting functions can be found on pages 134-136 in the maintenance section of this manual. CHILDREN: Before you ride your new Polaris ATV, there are some important things you should know. How to keep safe is the most important thing - 2002 Polaris Universal Youth ATV | Owners Manual - Page 19
KNOW YOUR MACHINE Pay attention when you see this symbol.: This is the safety alert symbol. When you see this symbol on your machine or in this manual it means PAY ATTENTION. If you don't, you could get hurt very badly or even killed. Your safety is involved! R--3 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 20
KNOW YOUR MACHINE Before you have an adult start the engine for you for the first time, let's learn about the controls on your new machine. 1. Engine Stop Switch (A) - When the engine is running, you can push this button down to shut the engine off. The button should be up "on" before starting the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 21
KNOW YOUR MACHINE 3. Kick Starter (B) - If your battery is too weak to start your machine, you can push on this with your foot to start the engine. Have an adult show you how this works. There is more information on how to use the kickstart on page 69. B 3 R--5 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 22
KNOW YOUR MACHINE 4. Gas Cap - This is where the gas goes that will run your ATV. Your ATV will not run without gas. Only adults should fill the gas tank. 1 4 Always have an adult put gas in your machine. R--6 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 23
KNOW YOUR MACHINE 5. Brake Lever (C) - Squeeze this towards the handle bar to make your ATV slow down or stop. The right hand lever (C-1) controls the front brake. The left hand lever (C-2) controls the rear brake. To slow down or stop, squeeze both brake handles at the same time. C-2 C-1 Always - 2002 Polaris Universal Youth ATV | Owners Manual - Page 24
KNOW YOUR MACHINE 6. Ignition Switch - This key must be turned "on" before pushing the starter button. You can also use this key to turn off the engine. You can find it on the Right-hand side of the Scramblers (D) and on the pod of the Sportsman (E). D E 6 R--8 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 25
KNOW YOUR MACHINE 7. Tether Strap/ Switch - This must always be attached snugly to your right wrist and your machine when you are riding. If you fall off your ATV, the tether will pull off the switch and the engine will stop. Put one end of the tether strap around your right wrist. The other end - 2002 Polaris Universal Youth ATV | Owners Manual - Page 26
KNOW YOUR MACHINE Let's review the three ways to stop your ATV. 1. Sliding the shut off switch to the left or right. 2. Disconnecting the tether strap will shut off the engine. 3. Turning the key to off will shut off the engine. R--10 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 27
KNOW YOUR MACHINE 3 1 2 R--11 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 28
PRE RIDE CHECK You are almost ready to have an adult start your ATV. Before the ATV is started for the first time, you must do a PRE-RIDE CHECK. In fact, every time you ride your ATV you must have an adult help you check these things before starting it. Let's learn about these things now. Make - 2002 Polaris Universal Youth ATV | Owners Manual - Page 29
PRE RIDE CHECK Make sure the brakes don't stick. Check the brake levers by squeezing them toward the handlebar and then letting it go. They should come right back to where they were before you squeezed. If they go back slowly or stay on, your brakes are sticking. If you have sticky brakes, do not - 2002 Polaris Universal Youth ATV | Owners Manual - Page 30
own gasoline. This should always be done by an adult. Before anyone adds gasoline to your ATV they must read the instructions and warnings on page 60 in this Owner's Manual. Always have an adult put gas in your machine. Have an adult check the engine oil level when the engine is - 2002 Polaris Universal Youth ATV | Owners Manual - Page 31
PRE RIDE CHECK This last check is done with the engine running. You must check to make certain that ALL THREE WAYS TO STOP your ATV are working the way they should. Do you remember what they are? If you cannot list them, go back to page R--10 and review. R--15 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 32
RIDING RULES Now you are ready to learn about riding a ATV. You will learn what you can do and what you cannot do. The adult with you is your teacher. You must listen and pay attention or you won't be safe when you ride. Remember that safety while you ride is the most important thing. Let's learn - 2002 Polaris Universal Youth ATV | Owners Manual - Page 33
RIDING RULES " Always wear the right kind of clothing when you are riding your ATV. You will need a good helmet with a face shield or goggles. Wear a long sleeved shirt or jacket, gloves, long pants, and boots. Make sure your clothing fits properly. If it is too small, it could keep you from moving - 2002 Polaris Universal Youth ATV | Owners Manual - Page 34
RIDING RULES You must always follow the safe riding rules found on the next pages. If you do not, you could be hurt really bad or even killed. " Never ride alone. An adult should always be watching you in case you need help. Always drive within the sight of an adult. " Never ride on public trails. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 35
RIDING RULES " 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. " Don't ride at night. " Learn where there are lakes, rivers, ponds and ditches in your driving area. Stay away from them. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 36
RIDING RULES " Never follow another ATV too closely. Always allow lots of time and space to stop your ATV. " Only ride your ATV where you know it is safe to drive. No driving over the flower garden or on the little trees you planted. Be careful of the things around you. " Always attach the tether - 2002 Polaris Universal Youth ATV | Owners Manual - Page 37
and safe way to ride any ATV. This should be done by reading the owner's manual with your children before they first use the ATV and periodically afterwards. . SAFETY TRAINING When were provided with certain printed material and a video which instructs operators on safe operating procedures. 1 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 38
can result in severe INJURY OR DEATH. NOTE: Illustrations used in this manual are for general representation only. Your model may differ. SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. Read all - 2002 Polaris Universal Youth ATV | Owners Manual - Page 39
UNDERSTANDING WARNINGS The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety is involved! - 2002 Polaris Universal Youth ATV | Owners Manual - Page 40
this manual to convey the following messages: Indicates a potential hazard which may result in minor personal injury or damage to the ATV. Indicates a situation that can result in damage to the machine. NOTE 4 The word "NOTE:" in this manual will alert you to key information or instructions. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 41
AND DESCRIPTION OF LABELS NOTE: Warning decals have been placed on the vehicle for the protection of the operator(s). Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal - 2002 Polaris Universal Youth ATV | Owners Manual - Page 42
GENERAL SAFETY AND DESCRIPTION OF LABELS WARNING 1 6 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 43
; 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 and control LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR - 2002 Polaris Universal Youth ATV | Owners Manual - Page 44
an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owner's Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. S Never operate this ATV on HILLS steeper than - 2002 Polaris Universal Youth ATV | Owners Manual - Page 45
an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owner's Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. S Never operate this ATV on HILLS steeper than - 2002 Polaris Universal Youth ATV | Owners Manual - Page 46
an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owner's Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. S Never operate this ATV on HILLS steeper than - 2002 Polaris Universal Youth ATV | Owners Manual - Page 47
an increased chance of losing control, which could result in severe injury or death. S Adult supervision is required. S Make sure operators follow Owner's Manual and labels. S Make sure operators watch the safety video and pass the ATV Training Course. S Never operate this ATV on HILLS steeper than - 2002 Polaris Universal Youth ATV | Owners Manual - Page 48
GENERAL SAFETY AND DESCRIPTION OF LABELS 4 3 3 WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control, resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 3 REAR 3 maximum weight capacity (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS _____ LBS. 12 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 49
GENERAL SAFETY AND DESCRIPTION OF LABELS 4 WARNING Indicates a potential hazard which could result in severe injury or death. 13 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 50
GENERAL SAFETY AND DESCRIPTION OF LABELS 6 5 14 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 51
vehicle without the and adjustments are filter element will severely damrequired depending on temperature age the engine. and altitude. See your Owner's Manual. DClean air filter often, more Factory Setting: frequent cleaning required in D 40 ° to 80 ° F. at 0-3000 feet. (5° to 27° dusty conditions - 2002 Polaris Universal Youth ATV | Owners Manual - Page 52
GENERAL SAFETY AND DESCRIPTION OF LABELS 8 8 10 7 16 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 53
GENERAL SAFETY AND DESCRIPTION OF LABELS 7 WARNING Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in - 2002 Polaris Universal Youth ATV | Owners Manual - Page 54
best. For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the rack. Read Owner's Manual for more detailed loading information. 18 (Found on Sportsman 90) - 2002 Polaris Universal Youth ATV | Owners Manual - Page 55
LABELS WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is skills learned in the course and the operating techniques described in the Owner's Manual. For more information about the training course, contact an authorized ATV dealer or - 2002 Polaris Universal Youth ATV | Owners Manual - Page 56
DAILY PRE-RIDE INSPECTION This ATV must be inspected each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. WARNING Use the following checklist to verify your machine is in proper working order each time you ride. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 57
DAILY PRE-RIDE INSPECTION 6. Engine stop switch - check for proper function 7. Wheels - check for tightness of wheel nuts and axle nuts; check that axle nuts are secured by cotter pins 8. Drive chain - condition and slack; refer to drive chain adjustment 9. Air cleaner element - check for dirt; - 2002 Polaris Universal Youth ATV | Owners Manual - Page 58
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Use by children of ATVs that are not recommended for their age can lead to severe injury or death of the child. Even though a child may be within the age group for which some ATVs are - 2002 Polaris Universal Youth ATV | Owners Manual - Page 59
OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger. The long seat is to - 2002 Polaris Universal Youth ATV | Owners Manual - Page 60
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to - 2002 Polaris Universal Youth ATV | Owners Manual - Page 61
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to - 2002 Polaris Universal Youth ATV | Owners Manual - Page 62
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident. Operating without eye - 2002 Polaris Universal Youth ATV | Owners Manual - Page 63
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume - 2002 Polaris Universal Youth ATV | Owners Manual - Page 64
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV at excessive speeds. WHAT CAN HAPPEN Increases your chances of losing control of the ATV, which can result in an accident. HOW TO AVOID THE HAZARD Always travel at a speed which is proper for the terrain, visibility and operating - 2002 Polaris Universal Youth ATV | Owners Manual - Page 65
OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don't try to show off. 29 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 66
use it to make sure the ATV is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner's Manual. 30 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 67
OPERATION WARNINGS WARNING POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can reduce your ability to control the ATV or could cause you to lose your balance and fall off the ATV. If you remove a foot from the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 68
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on unfamiliar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, without enough time to react. Could result in the ATV overturning or going out of control. HOW TO AVOID THE HAZARD Go - 2002 Polaris Universal Youth ATV | Owners Manual - Page 69
OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on - 2002 Polaris Universal Youth ATV | Owners Manual - Page 70
could go out of control, causing a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the Owner's Manual. See page 86 . Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. 34 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 71
loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the Owner's Manual. See pages 91 through 96. Always check the terrain carefully before you start up any hill. Never climb hills with excessively slippery or loose - 2002 Polaris Universal Youth ATV | Owners Manual - Page 72
of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner's Manual. See page 94. NOTE: A special technique is required when braking as you go downhill. Always check the terrain carefully before you start down any hill - 2002 Polaris Universal Youth ATV | Owners Manual - Page 73
AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner's Manual on level ground. See page 96. Be very careful when turning on any hill. Avoid crossing the side of a steep hill if possible. When crossing - 2002 Polaris Universal Youth ATV | Owners Manual - Page 74
. Dismount on uphill side, or to either side if pointed straight uphill. Turn the ATV around and remount, following the procedure described in the Owner's Manual. See page 96. 38 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 75
OPERATION WARNINGS WARNING POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN You may lose control of the ATV. You may also regain traction unexpectedly, which may cause the ATV to overturn. HOW TO AVOID THE HAZARD On slippery surfaces, such as ice, go slowly and be very cautious in order to - 2002 Polaris Universal Youth ATV | Owners Manual - Page 76
riding over large obstacles, such as large rocks or fallen trees. If you cannot avoid obstacles, always follow proper procedures as described in the Owner's Manual. 40 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 77
OPERATION WARNINGS WARNING POTENTIAL HAZARD Riding on frozen lakes and rivers. WHAT CAN HAPPEN Severe injury or death can result if the ATV and/or the operator break through the ice. HOW TO AVOID THE HAZARD Never ride your ATV on a frozen body of water. 41 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 78
OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV through deep or fast flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water. If - 2002 Polaris Universal Youth ATV | Owners Manual - Page 79
of control, and increases the risk of an accident. HOW TO AVOID THE HAZARD Always use the size and type tires specified in the Owner's Manual Supplement for this vehicle. Always maintain proper tire pressure as described in the Owner - 2002 Polaris Universal Youth ATV | Owners Manual - Page 80
OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this ATV WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. 44 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 81
OPERATION WARNINGS WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this rider active vehicle - 2002 Polaris Universal Youth ATV | Owners Manual - Page 82
this vehicle should be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV; and should be installed and used according to instructions. If you have questions, consult an authorized Polaris ATV dealer. 46 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 83
VEHICLE IDENTIFICATION NUMBERS 1 2 47 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 84
VEHICLE IDENTIFICATION NUMBERS Using the illustration on page 47, record these numbers from your ATV in the spaces provided. 1. Engine Serial Number (Left side of engine crankcase) 2. Frame VIN (found on the front of frame below steering post) Remove the spare key and store in a safe place. Your - 2002 Polaris Universal Youth ATV | Owners Manual - Page 85
CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1 - Main Switch - Located on the Right-hand side of the Scramblers (A) and on the pod of the Sportsman (B). This switch is operated with a key and must be turned clockwise to the "on" position to start the engine. A B 1 49 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 86
CONTROL AND PARTS FUNCTIONS 2 - Emergency Engine Stop Switch The engine will not start or run when the switch is in its "off" position. Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency. NOTE: Both the main switch and the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 87
CONTROL AND PARTS FUNCTIONS 3 - Engine Start Button - To start the engine, make certain the tether switch is securely plugged into the machine and attached to the rider's right wrist. Turn the key to the "on" position, set the parking brake, push the start button up to the "on" position and engage - 2002 Polaris Universal Youth ATV | Owners Manual - Page 88
CONTROL AND PARTS FUNCTIONS CAUTION Engine or driveline damage could occur if the machine is driven without the park brake released. WARNING This ATV is not equipped with lighting. This ATV is designed for off-road use only and must not be ridden on streets or highways. Use caution and drive at - 2002 Polaris Universal Youth ATV | Owners Manual - Page 89
A stuck or improperly operating throttle could cause an accident resulting in severe injury or death. Always contact your dealer for service repairs whenever throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in the throttle lever sticking during - 2002 Polaris Universal Youth ATV | Owners Manual - Page 90
CONTROL AND PARTS FUNCTIONS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with an Electronic Throttle Control (ETC) which is - 2002 Polaris Universal Youth ATV | Owners Manual - Page 91
CONTROL AND PARTS FUNCTIONS WARNING The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanism. 55 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 92
CONTROL AND PARTS FUNCTIONS Switches Each Polaris ATV has a main switch. It is located on the right hand side of the machine or headlight pod and operated with a key. Indicator Lights Each Polaris ATV has indicator lights. This model has a low oil warning light. When this red dot is lit, it is - 2002 Polaris Universal Youth ATV | Owners Manual - Page 93
CONTROL AND PARTS FUNCTIONS Front and Rear Brakes To activate the rear brake (A), squeeze the left hand lever toward the handlebar. The front brakes (B) are activated by squeezing the lever on the RH handlebar. B WARNING Always apply both brakes at the same time or loss of vehicle control can occur - 2002 Polaris Universal Youth ATV | Owners Manual - Page 94
CONTROL AND PARTS FUNCTIONS Parking Brake WARNING Always check to be sure that the parking brake has been disengaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated. Setting the Parking Brake 1. Squeeze the left - 2002 Polaris Universal Youth ATV | Owners Manual - Page 95
CONTROL AND PARTS FUNCTIONS 3. To release the parking brake lock, squeeze the brake lever. The parking brake will release automatically. Important Safeguards NOTE: This vehicle has a PVT system which is always in forward. Always lock the park brake before starting the engine. Always lock the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 96
CONTROL AND PARTS FUNCTIONS Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D D Always refuel with the engine stopped and outdoors or in a well ventilated area. WARNING Do not smoke or allow open flames or sparks - 2002 Polaris Universal Youth ATV | Owners Manual - Page 97
CONTROL AND PARTS FUNCTIONS WARNING Indicates a potential hazard which could result in severe injury or death. WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. 61 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 98
CONTROL AND PARTS FUNCTIONS PVT System The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure - 2002 Polaris Universal Youth ATV | Owners Manual - Page 99
CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. The tank has a capacity of 1.3 gallons (5 liters). Use unleaded gasoline with a minimum pump octane number of 87 octane. 1 63 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 100
CONTROL AND PARTS FUNCTIONS The fuel valve is located on the engine, behind the right front fender and has three positions: OFF: For vehicle storage and whenever transporting. ON: For normal operation. RES: For reserve supply in the event of main supply exhaustion. NOTE: There is about a 7 to 10 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 101
CONTROL AND PARTS FUNCTIONS Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with an in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter. Use only Polaris injection oil. Never substitute - 2002 Polaris Universal Youth ATV | Owners Manual - Page 102
CONTROL AND PARTS FUNCTIONS Oil System The oil tank (1) is located under the seat and has a capacity of 1.1 quarts (1 liter). To remove the seat, reach under the rear of the cab and pull back on the seat latch. To replace the seat, set it in place and push down on the rear of seat. Always make sure - 2002 Polaris Universal Youth ATV | Owners Manual - Page 103
CONTROL AND PARTS FUNCTIONS CAUTION Engine warranty coverage may become void if you use a brand other than Polaris in your machine. Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for - 2002 Polaris Universal Youth ATV | Owners Manual - Page 104
CONTROL AND PARTS FUNCTIONS Polaris Premium 2-cycle lubricants are the most advanced formulation of oils specifically designed for today's 2-cycle engines. Months of lab and field tests have resulted in a new generation of 2-cycle lubricants. Polaris Premium 2-cycle lubricants provide additives for - 2002 Polaris Universal Youth ATV | Owners Manual - Page 105
CONTROL AND PARTS FUNCTIONS Kick Starter If the battery is weak and cannot start the engine, kick start lever will allow vehicle operation until repairs can be made. 1. Be certain your vehicle is on a level surface and the parking brake is set. See page 58. 2. Fold out the kick start lever (A) which - 2002 Polaris Universal Youth ATV | Owners Manual - Page 106
STARTING THE ENGINE Procedure for Starting a Cold Engine WARNING Indicates a potential hazard which could result in severe injury or death. WARNING Never run an engine in an enclosed area. Carbon monoxide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors - 2002 Polaris Universal Youth ATV | Owners Manual - Page 107
STARTING THE ENGINE Set the parking brake. Turn the fuel tank valve to ON. Sit on the vehicle. Attach tether strap to machine and wrist. Turn the engine stop switch to RUN. Turn the ignition key to ON. Press the starter button. NOTE: The rear brake lever must be engaged or the engine will not start. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 108
RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 109
RIDING GEAR 2. Eye Protection Do not depend on sunglasses for proper eye protection. A pair of goggles or helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings z2.1 or VESC 8). 3. Gloves Off-road style gloves with - 2002 Polaris Universal Youth ATV | Owners Manual - Page 110
VEHICLE BREAK-IN PERIOD 2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient - 2002 Polaris Universal Youth ATV | Owners Manual - Page 111
VEHICLE BREAK-IN PERIOD 3. Drive slowly at first. Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling. CAUTION Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Excessive heat can - 2002 Polaris Universal Youth ATV | Owners Manual - Page 112
VEHICLE BREAK-IN PERIOD After the break in period the oil injection system provides the necessary engine lubrication without the need for pre-mixed fuel. CAUTION Fill the oil tank when you refuel your ATV. If you don't serious engine damage could result. After the first tank of pre-mixed fuel has - 2002 Polaris Universal Youth ATV | Owners Manual - Page 113
CARRYING LOADS The Sportsman 90 has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving - 2002 Polaris Universal Youth ATV | Owners Manual - Page 114
CARRYING LOADS 2/3 of Load on Rear Rack 1/3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: D D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. CARGO WEIGHT DISTRIBUTION - 2002 Polaris Universal Youth ATV | Owners Manual - Page 115
CARRYING LOADS D HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations which may require backing downhill. ALL LOADS MUST BE SECURED BEFORE MOVING - 2002 Polaris Universal Youth ATV | Owners Manual - Page 116
CARRYING LOADS D EXTREME CAUTION MUST BE USED when operating with loads extending over the rack sides. Stability and maneuverability may be adversely affected, causing the machine to overturn. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. D 80 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 117
DAILY PRE-RIDE CHECK WARNING You must inspect your ATV each time before riding to ensure it is in proper working order. If proper check is not done, severe injury or death could result. 81 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 118
DAILY PRE-RIDE CHECK Use the following checklist to verify your machine is in proper working order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation and adjustment. 4. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 119
DAILY PRE-RIDE CHECK 8. Drive chain - condition and slack; refer to drive chain adjustment 9. Air cleaner element - check for dirt; clean or replace 10. Steering - check for free operation noting any unusual looseness in any area 11. Loose parts - visually inspect vehicle for any damaged or loose - 2002 Polaris Universal Youth ATV | Owners Manual - Page 120
RIDING 84 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 121
RIDING 1. 2. 3. 4. 5. Sit upright with both feet on the footrests and both hands on the handlebars. Start the engine and allow it to warm up. Check your surroundings and determine your path of travel. Release the parking brake. Slowly depress the throttle with your right thumb and begin driving. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 122
RIDING Making Turns 86 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 123
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. WARNING - 2002 Polaris Universal Youth ATV | Owners Manual - Page 124
RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. 88 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 125
RIDING Always: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns which can cause skids. 3. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward. 4. Never apply - 2002 Polaris Universal Youth ATV | Owners Manual - Page 126
RIDING Traveling Uphill 15_ Maximum 90 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 127
RIDING WARNING Do not operate this machine on hilly terrain. If you cannot avoid operating in hilly terrain, use extreme caution. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing severe injury or death. If you have to travel uphill - 2002 Polaris Universal Youth ATV | Owners Manual - Page 128
RIDING Sidehilling 92 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 129
RIDING Avoid traveling across the side of a hill at all costs. In the event you do enter into a situation where sidehilling is unavoidable, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight up hill while keeping your feet on the footrests. 3. Steer slightly into the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 130
RIDING Traveling Downhill 94 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 131
RIDING Whenever descending a hill, always: 1. 2. 3. 4. Drive directly downhill. Transfer your weight to the rear of the vehicle. Slow down. Apply the the front and rear brakes at the same time and very slightly to aid in slowing. WARNING Do not travel at excessive speeds. It is dangerous and can - 2002 Polaris Universal Youth ATV | Owners Manual - Page 132
RIDING Turning Around On A Hill 8' Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 96 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 133
off engine. Dismount on left or uphill side of ATV. Staying uphill of ATV, turn handlebars full left (while facing front of ATV). While holding service brake, release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly downward - 2002 Polaris Universal Youth ATV | Owners Manual - Page 134
RIDING Crossing Streams Your Polaris ATV can operate through water up to depths just below the footrests. 98 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 135
sudden turns or stops and do not make sudden throttle changes. NOTE: If the vehicle is run in water, it is critical the machine is serviced as outlined in the maintenance chart beginning on page 117. The following areas need special attention: engine oil, transmission oil, front and rear gearcases - 2002 Polaris Universal Youth ATV | Owners Manual - Page 136
RIDING Trail Obstacles 100 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 137
RIDING Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Not all obstacles are visible. Travel with caution on trails. severe injury or death can result - 2002 Polaris Universal Youth ATV | Owners Manual - Page 138
RIDING Parking on an Incline 102 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 139
RIDING Whenever the Vehicle is Parked 1. Turn the engine off. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown on the facing page. 4. Shut off fuel supply. 103 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 140
PVT SYSTEM OPERATION PVT System The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to insure the safety of this product. However, as the owner you have the following responsibilities to make sure this - 2002 Polaris Universal Youth ATV | Owners Manual - Page 141
PVT SYSTEM OPERATION If the vehicle is operated in dusty areas, it will be necessary to clean the filter more often. To clean the PVT filter: 1. Remove the screws and the crankcase cover. 2. Remove the screws and the filter cover. 3. Soak the filter in a mild detergent and rinse with clean water. 4. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 142
BATTERY Battery Only adults should ever touch the battery. Never allow children to handle a battery or service a battery in any way. WARNING WARNING Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable - 2002 Polaris Universal Youth ATV | Owners Manual - Page 143
BATTERY WARNING Indicates a potential hazard which could result in severe injury or death. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities - 2002 Polaris Universal Youth ATV | Owners Manual - Page 144
BATTERY Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks. To refill use only distilled water. Tap water contains minerals which are harmful to a battery. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 145
Battery Removal BATTERY 1. Disconnect hold down straps holding the electrical box and battery in position. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable next. 4. Lift the battery out of the ATV, being careful not to tip it sideways and spill - 2002 Polaris Universal Youth ATV | Owners Manual - Page 146
BATTERY Battery Installation and Connections WARNING To avoid the possibility of explosion, always connect battery cables in the order specified. Red (positive) cable first; black (negative) cable last. An exploding battery can cause serious injury or death. Battery terminals and connections should - 2002 Polaris Universal Youth ATV | Owners Manual - Page 147
BATTERY 1. Set the battery in its holder. 2. First connect and tighten the red (positive) cable. 3. Second connect and tighten the black (negative) cable. 4. Attach the hold down strap. 5. Verify that cables are properly routed. NOTE: D D D When your ATV is placed in storage for three months or more - 2002 Polaris Universal Youth ATV | Owners Manual - Page 148
NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or - 2002 Polaris Universal Youth ATV | Owners Manual - Page 149
NOISE EMISSION CONTROL SYSTEM REGULATION 2. Removal or alteration or the puncturing of any part of the engine air induction system. 3. Replacement of any vehicle parts with parts not in compliance with federal regulations. 4. Lack of proper maintenance. CAUTION Engine and exhaust parts can become - 2002 Polaris Universal Youth ATV | Owners Manual - Page 150
NOISE EMISSION CONTROL SYSTEM REGULATION USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. 114 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 151
MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are: 2-cycle engines D D spark plug wrench with Phillips head screwdriver tire pressure gauge Periodic Maintenance Schedule Careful periodic - 2002 Polaris Universal Youth ATV | Owners Manual - Page 152
. Vehicles subjected to severe use, such as operation in wet or dusty areas, should be inspected and serviced more frequently. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Inspect, clean, lubricate, adjust or replace parts as - 2002 Polaris Universal Youth ATV | Owners Manual - Page 153
MAINTENANCE " More often under severe use, such as dirty or wet conditions Item Brake System Tires Wheels Frame nuts, bolts, fasteners Oil Level " J Air Filter Brake pad wear Hours or Miles Pre-ride Pre-ride Pre-ride Pre-ride Daily Daily 10 hrs/100 miles 20 hrs When Remarks Pre-ride Pre-ride - 2002 Polaris Universal Youth ATV | Owners Manual - Page 154
Periodic Maintenance Schedule (Cont.) CAUTION Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions Item Oil Pump Cable Carburetor - 2002 Polaris Universal Youth ATV | Owners Manual - Page 155
MAINTENANCE Item J " " " " " J Throttle Cable/ ETC Switch Steering Rear Axle Front Suspension Rear Suspension Drive Chain Clutches (drive and driven) Hours or Miles 50 hrs 50 hrs 50 hrs 50 hrs 50 hrs 50 hrs 100 hrs When 6 months 6 months 6 months 6 months 6 months 6 months 12 months Remarks Inspect- - 2002 Polaris Universal Youth ATV | Owners Manual - Page 156
MAINTENANCE CAUTION Due to the nature of the adjustments marked with a J on the following chart, it is recommended that service be performed by an authorized Polaris dealer. " More often under severe use, such as dirty or wet conditions Item Engine Mounts Spark Plug J 120 Ignition - 2002 Polaris Universal Youth ATV | Owners Manual - Page 157
MAINTENANCE Item J Fuel System Hours or Miles 100 hours 100 hrs 100 hrs 300 hrs As Required As required When 12 months 12 months 12 months 36 months As Required As required Remarks Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years. Replace - 2002 Polaris Universal Youth ATV | Owners Manual - Page 158
MAINTENANCE Lubrication Recommendations Item 1. Engine Oil Lube Rec. Polaris Injection Oil Method Fill oil tank. See page 63. Frequency* As needed, when refueling Change annually or at 100 hours 2. Transmission Oil Polaris See Page 148 Premium Synthetic gear case lube 122 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 159
Lubrication Recommendations MAINTENANCE 2. Transmission (plug) Operating Range 123 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 160
500 miles, or after submerging in water or before long periods of storage or after pressure washing. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.). ∆ When suspension action becomes stiff or after washing. 124 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 161
NOTE: Hours are based on 10 mph average. MAINTENANCE 4. 125 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 162
MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs. Servicing Servicing Date Dealer or Person Remarks 126 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 163
MAINTENANCE Maintenance Interval Performed Servicing Servicing Date Dealer or Person Remarks 127 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 164
MAINTENANCE 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. Handlebar Adjustment Your ATV has handlebars - 2002 Polaris Universal Youth ATV | Owners Manual - Page 165
MAINTENANCE 2. Loosen the four bolts. 3. Adjust handlebar to desired height. Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right. 4. Torque handlebar adjuster block bolts to 7.3 ft. lbs. NOTE: Tighten bolts so there is an equal gap at the front and - 2002 Polaris Universal Youth ATV | Owners Manual - Page 166
occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Specification Front Spindle Nuts Rear NOTE: All nuts that have a cotter pin installed must be serviced by an authorized Polaris Dealer. Front Wheel Hub Tightening Front wheel - 2002 Polaris Universal Youth ATV | Owners Manual - Page 167
MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment Cam 131 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 168
MAINTENANCE Air Cleaner Inspect the filter weekly or after every 50 hours of operation. If the vehicle is ridden in wet or dusty conditions, clean the filter more often. CAUTION Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid wear and damage - 2002 Polaris Universal Youth ATV | Owners Manual - Page 169
MAINTENANCE To clean the filter: 1. Remove the screws on the airbox (A) and remove the filter (B). 2. Soak the filter in a mild detergent and rinse it in clean water. 3. Let the filter air dry and reinstall in the air box. A B 133 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 170
MAINTENANCE Throttle Stop System The throttle stop system controls how far the throttle opens. To adjust, loosen the jam nut (D), turn the screw (E) inward to reduce speed and outward to increase speed. Tighten the jam nut after adjusting. D E 134 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 171
MAINTENANCE Exhaust System Restrictor The exhaust restrictor system restricts exhaust gas flow, reducing the maximum power output of the engine. Exhaust System Restrictor Removal A The Scrambler 50 utilizes a restrictor at the headpipe exhaust flange and at the spark arrestor. Make certain the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 172
MAINTENANCE Lower the exhaust system and remove the restrictor washer (A). Re-install the head pipe exhaust flange nuts, the center mount bolt, and the spark arrestor fasteners. Torque the spark arrestor first, then the center mount bolt and the head pipe flange nuts last. Torque to 10 ft. lbs. (1.0 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 173
MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. WARNING Do not - 2002 Polaris Universal Youth ATV | Owners Manual - Page 174
MAINTENANCE Toe Alignment You can check the toe alignment of the vehicle using the following method. The recommended toe alignment is 1/8″ to 1/4″ (.3 to .6 cm) toe out. If you discover improper adjustment have your dealer correct it. 1. Set the handlebars in a straight ahead position and hold them - 2002 Polaris Universal Youth ATV | Owners Manual - Page 175
rim. Rear rim measurement should be 1/16″ - 1/8″ (.2 to .3 cm) more than front rim measurement. 5. If this measurement needs to be adjusted, contact your dealer for service. 139 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 176
140MAINTENANCE Brake Adjustment Periodically check the freeplay of the front and rear brakes. Refer to the chart below for the acceptable range of freeplay for your machine. To adjust the front brake, turn the adjustment knob (A) until the freeplay is acceptable. A 140 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 177
MAINTENANCE To adjust the rear brake, turn the adjuster nut (B) until the proper freeplay is attained. B 141 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 178
MAINTENANCE Brake Freeplay Adjustment Model Sportsman 90 Scrambler 90 Scrambler 50 Front .39″ - .78″ 10 mm - 20 mm .39″ - .78″ 10 mm - 20 mm .1″ - .39 ″ 2.5mm - 9.9 mm Rear .39″ - .78″ 10 mm - 20 mm .39″ - .78″ 10 mm - 20 mm .15″ - .30″ 3.8mm - 7.6mm 142 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 179
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 ″ (1.5mm - 3.2mm) (C). If adjustment is required, turn the adjustment nut (D) until the freeplay falls in to the - 2002 Polaris Universal Youth ATV | Owners Manual - Page 180
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. NOTE: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetion - 2002 Polaris Universal Youth ATV | Owners Manual - Page 181
MAINTENANCE 2. Wet Fouled The 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 are excessive oil, use of non-recommended injection oil, improper use of the choke, or incorrect - 2002 Polaris Universal Youth ATV | Owners Manual - Page 182
corrosion of engine parts. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged, following the fogging instructions on the can. Always add a fuel conditioner/stabilizer to the fuel tank. Run the engine for five minutes to get the additives through the entire - 2002 Polaris Universal Youth ATV | Owners Manual - Page 183
MAINTENANCE Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. WARNING Indicates a potential hazard which could result in severe injury or death. 147 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 184
MAINTENANCE Transmission Lubrication The transmission dipstick (A) is located on the top of the transmission. The transmission lubricant level should be checked monthly. Transmission oil should be changed annually. With the ATV on a level surface, remove fill plug dipstick and check the lubricant - 2002 Polaris Universal Youth ATV | Owners Manual - Page 185
MAINTENANCE Transmission Oil Changing Procedure 1. Remove fill plug/dipstick. 2. Remove transmission drain plug and drain the oil. Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to full mark - 2002 Polaris Universal Youth ATV | Owners Manual - Page 186
MAINTENANCE WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling which could cause an accident resulting in serious injury or death. Follow the safeguards listed below to prevent this type of situation. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 187
MAINTENANCE Important Safeguards Maintain proper tire pressure according to chartson page 152. Improper tire inflation may affect ATV maneuverability. Do not use improper tires. The use of non-standard size or type tires may affect ATV handling. Make certain the wheels are installed properly. If - 2002 Polaris Universal Youth ATV | Owners Manual - Page 188
MAINTENANCE Tire Size Scrambler 50 Scrambler 90 Front Rear Front Rear Sportsman 90 Front Rear PSI Wheel Nut Torque 16 x 8 - 7 16 x 8 - 7 18 x 7 - 7 18 x 9.5 - 8 19 x 7 - 8 18 x 9.5 - 8 2 2 3 3 3 3 22 ft. lbs 22 ft. lbs 22 ft. lbs 22 ft. lbs 22 ft. lbs 22 ft. lbs 152 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 189
MAINTENANCE Wheel Installation 1. With the park brake locked, 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. 2. Attach the wheel nuts and finger tighten them. 3. Lower the vehicle - 2002 Polaris Universal Youth ATV | Owners Manual - Page 190
MAINTENANCE Tire Inspection When replacing a tire always use original equipment size and type. 1 Tire Tread Depth Always replace tires when tread depth is worn to 1/8″ (.3 cm) (1) or less. 154 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 191
MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION Never wash the chain with a high pressure washer or gasoline. Damage - 2002 Polaris Universal Youth ATV | Owners Manual - Page 192
MAINTENANCE Drive Chain Inspection and Adjustment (Cont.) CAUTION The adjuster stud must be held secure when tightening jam nuts or the stud may break. 156 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 193
Rear Drive Chain Slack Adjustment MAINTENANCE Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. The normal chain slack should be kept between .40″ .80″ 〈10-20 mm) (A). CAUTION A 1 157 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 194
MAINTENANCE Adjustment Procedure 1. Loosen 4 rear housing mount bolts (A). 2. Tighten chain adjuster (B) to reduce slack to recommended setting. (.4″ - .8″ / 10 mm - 20 mm) 3. Tighten jam nuts on chain adjuster. 4. Tighten the four rear housing mount bolts. A B 158 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 195
MAINTENANCE Brakelight Lamp Replacement If the brakelight does not work the lamp may need to be replaced. 1. From the rear of the brake light remove two screws (A) holding lens cover in place and remove lens cover (B). 2. Remove lamp (C) and replace it with recommended lamp. 3. Test the brakelight - 2002 Polaris Universal Youth ATV | Owners Manual - Page 196
MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be - 2002 Polaris Universal Youth ATV | Owners Manual - Page 197
MAINTENANCE The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water. Use a professional type washing mitten, cleaning the upper body first and the lower parts last. Rinse with water frequently and dry with a chamois to prevent water spots. NOTE: If warning - 2002 Polaris Universal Youth ATV | Owners Manual - Page 198
MAINTENANCE Transporting Whenever the ATV is to be transported the following measures should be taken. 1. Turn the fuel valve to off. 2. Be certain the fuel cap, oil cap, and seat are installed correctly. 3. Always tie the frame of the ATV to the transporting unit securely using suitable straps or - 2002 Polaris Universal Youth ATV | Owners Manual - Page 199
MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich. An engine loses approximately 3% of its - 2002 Polaris Universal Youth ATV | Owners Manual - Page 200
SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Scrambler 50 1 49cc Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liter) 1.3 gallons (5 liters) Electric with kick-start - 2002 Polaris Universal Youth ATV | Owners Manual - Page 201
SPECIFICATIONS Front/Rear Brakes Parking Brake Front Tires / PSI Rear Tires / PSI Turning Radius Wheel Base Dry Weight Length Width Height Brake Light Low Oil Light Specifications - Scrambler 50 Drum Mechanical Lock 16 x 8-7 (2psi) 18 x 9.5 - 8 (2psi) 74.8″ (190 cm) 35.4″ (90 cm) 211.6 lbs (96 kgs) - 2002 Polaris Universal Youth ATV | Owners Manual - Page 202
SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Scrambler 90 1 89cc Fan Cooled 2-Stroke Oil Injected 1.1 quarts (1 liter) 1.3 gallons (5 liters) Electric with kick-start - 2002 Polaris Universal Youth ATV | Owners Manual - Page 203
SPECIFICATIONS Specifications - Scrambler 90 Front/Rear Brakes Drum Parking Brake Mechanical Lock Front and Rear Tires / PSI 18 x 7 - 7 (2psi) Turning Radius 98.4″ (250 cm) Wheel Base 35.4″ (90 cm) Dry Weight 233.7 lbs (106 kgs) Length 56.1″ (142.4 cm) Width 34″ (86.3 cm) Height 36.1″ (91.8 cm) - 2002 Polaris Universal Youth ATV | Owners Manual - Page 204
SPECIFICATIONS Rider Capacity Displacement Cooling Engine type Lubrication Oil Capacity Fuel Capacity Starting Transmission Front Suspension Rear Suspension Specifications - Sportsman 90 1 89cc Fan Cooled 2-Stroke Oil Injected 1.1 qts. (1 ltr) 1.3 ga. (5 ltr) Electric with kick-start backup - 2002 Polaris Universal Youth ATV | Owners Manual - Page 205
SPECIFICATIONS Front/Rear Brakes Parking Brake Front Tires / PSI Rear Tires / PSI Wheel Base Turning Radius Dry Weight Length Width Height Brake Light Specifications - Sportsman 90 Drum Mechanical Lock 19 x 7 - 8 (3 psi) 18 x 9.5 - 8 (3 psi) 37.8″ (96 cm) 98.4″ (250 cm) 238.1 lbs (108 kgs) 57.6″ ( - 2002 Polaris Universal Youth ATV | Owners Manual - Page 206
SPECIFICATIONS Specifications - Sportsman 90 Low Oil Light Front Rack Capacity Rear Rack Capacity Standard 10 lb (4.5 kgs) 20 lb (9 kgs) Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories available for your - 2002 Polaris Universal Youth ATV | Owners Manual - Page 207
WIRING DIAGRAM 171 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 208
WIRING DIAGRAM 172 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 209
TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your - 2002 Polaris Universal Youth ATV | Owners Manual - Page 210
TROUBLESHOOTING ENGINE STOPS OR LOSES POWER No Fuel Turn Fuel Valve to "Res" Fuel Vent Line Kinked or Plugged Water in Fuel 174 Spark Plug Fouled Air Filter Clogged Electronic Throttle Control Malfunction Contact Your Dealer Engine Overheated Clean Engine Exterior Contact Your Dealer - 2002 Polaris Universal Youth ATV | Owners Manual - Page 211
WARRANTY LIMITED WARRANTY Polaris Industries 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 material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for - 2002 Polaris Universal Youth ATV | Owners Manual - Page 212
COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS. Initial dealer preparation and set--up of your ATV is very important in ensuring trouble--free operation. Purchasing a machine in the crate or without proper dealer set--up will void your warranty coverage. 176 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 213
for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing - 2002 Polaris Universal Youth ATV | Owners Manual - Page 214
WARRANTY 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 replacement of any defective materials, or components or products. - 2002 Polaris Universal Youth ATV | Owners Manual - Page 215
inconsistent with controlling state law. 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 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 216
WARRANTY Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance they will contact the appropriate person 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 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 217
INDEX Air Cleaner ...132 Battery Installation ...110 Battery Maintenance ...106 Battery Removal ...109 Brake Adjustment ...140 Brake Freeplay Adjustment ...142 Brake Lever ...R7 Brake, Parking ...58 Brakelight Lamp Replacement . . 159 Brakes, Front ...57 Brakes, Rear ...57 Break In Period ...74-76 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 218
100 Transmission Lubrication ...148 Transmission Oil Changing Procedure ...149 Transporting ...162 Traveling Downhill ...94 Traveling Uphill ...90 Troubleshooting ...173-174 Turning Around On A Hill ...96 Understanding Warnings ...1-4 Understanding Warnings . . R16-R20 Vehicle Identification Numbers - 2002 Polaris Universal Youth ATV | Owners Manual - Page 219
INDEX Warranty ...175-180 Wheel Installation ...151-153 Wheel Nut Torque ...152 Wheel Removal ...151 Wiring Diagram ...171-172 183 - 2002 Polaris Universal Youth ATV | Owners Manual - Page 220
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
-
1 -
2 -
3 -
4 -
5 -
6 -
7 -
8
-
9
-
10
-
11
-
12
-
13
-
14
-
15
-
16
-
17
-
18
-
19
-
20
-
21
-
22
-
23
-
24
-
25
-
26
-
27
-
28
-
29
-
30
-
31
-
32
-
33
-
34
-
35
-
36
-
37
-
38
-
39
-
40
-
41
-
42
-
43
-
44
-
45
-
46
-
47
-
48
-
49
-
50
-
51
-
52
-
53
-
54
-
55
-
56
-
57
-
58
-
59
-
60
-
61
-
62
-
63
-
64
-
65
-
66
-
67
-
68
-
69
-
70
-
71
-
72
-
73
-
74
-
75
-
76
-
77
-
78
-
79
-
80
-
81
-
82
-
83
-
84
-
85
-
86
-
87
-
88
-
89
-
90
-
91
-
92
-
93
-
94
-
95
-
96
-
97
-
98
-
99
-
100
-
101
-
102
-
103
-
104
-
105
-
106
-
107
-
108
-
109
-
110
-
111
-
112
-
113
-
114
-
115
-
116
-
117
-
118
-
119
-
120
-
121
-
122
-
123
-
124
-
125
-
126
-
127
-
128
-
129
-
130
-
131
-
132
-
133
-
134
-
135
-
136
-
137
-
138
-
139
-
140
-
141
-
142
-
143
-
144
-
145
-
146
-
147
-
148
-
149
-
150
-
151
-
152
-
153
-
154
-
155
-
156
-
157
-
158
-
159
-
160
-
161
-
162
-
163
-
164
-
165
-
166
-
167
-
168
-
169
-
170
-
171
-
172
-
173
-
174
-
175
-
176
-
177
-
178
-
179
-
180
-
181
-
182
-
183
-
184
-
185
-
186
-
187
-
188
-
189
-
190
-
191
-
192
-
193
-
194
-
195
-
196
-
197
-
198
-
199
-
200
-
201
-
202
-
203
-
204
-
205
-
206
-
207
-
208
-
209
-
210
-
211
-
212
-
213
-
214
-
215
-
216
-
217
-
218
-
219
-
220
 |
 |
