The Polaris Outlaw 90 is a popular choice for young riders venturing into the world of ATVs. Its manageable size and reliable engine make it a great starter machine. However, like any off-road vehicle, the Outlaw 90 isn't without its quirks, and one of the most common complaints centers around the chain. A loose, stretched, or broken chain can quickly sideline a fun ride, turning excitement into frustration for both rider and parent. Understanding the common causes of these chain issues and knowing how to address them is crucial for keeping your young rider safely on the trail.

Why is My Outlaw 90 Chain Giving Me Headaches?

Several factors can contribute to chain problems on the Polaris Outlaw 90. It's rarely a single cause but often a combination of things that lead to premature wear, stretching, or even breakage. Let's break down the common culprits:

  • Aggressive Riding: Let's face it, kids aren't always known for their gentle touch. Frequent hard acceleration, especially on rough terrain, puts significant stress on the chain. Think of it like repeatedly snapping a rubber band – eventually, it's going to lose its elasticity and possibly break.
  • Lack of Proper Lubrication: This is perhaps the most common reason for chain problems. A dry chain creates excessive friction, leading to rapid wear and stretching. Imagine running your car engine without oil – the same principle applies here.
  • Incorrect Chain Tension: Too tight, and the chain will bind and wear prematurely. Too loose, and it can skip off the sprockets, causing damage to both the chain and sprockets. Finding the sweet spot is key.
  • Cheap or Low-Quality Chain: The Outlaw 90's stock chain is adequate for normal use, but if you've replaced it with a cheap aftermarket option, you might be sacrificing durability. Investing in a quality chain from a reputable brand can save you headaches in the long run.
  • Worn Sprockets: The chain interacts directly with the front and rear sprockets. If these sprockets are worn, with hooked or damaged teeth, they'll accelerate the wear on the chain and can even cause it to jump off.
  • Debris and Dirt: Riding in muddy or sandy conditions can quickly contaminate the chain. Dirt acts like sandpaper, grinding away at the chain's components and accelerating wear.
  • Improper Chain Adjustment: Many times, the chain adjustment is not performed correctly, leading to over-tightening or improper alignment, both of which stress the chain.

Spotting the Trouble: Recognizing Chain Problems Early

The sooner you identify a chain issue, the easier (and cheaper!) it is to fix. Here's what to look for:

  • Excessive Slack: If the chain sags significantly between the sprockets, it's likely stretched and needs adjustment or replacement. A little slack is normal, but too much is a red flag.
  • Rust or Corrosion: Obvious signs of neglect. A rusty chain is a weak chain.
  • Stiff Links: If some links in the chain are noticeably stiffer than others, it indicates internal wear and binding.
  • Chain Skipping or Jumping: This usually happens when the chain is too loose or the sprockets are worn. You'll hear a distinct "clunking" sound.
  • Unusual Noises: Grinding, clicking, or rattling sounds coming from the chain area are all signs of potential problems.
  • Visible Damage: Look for cracked, bent, or missing links. Any visible damage warrants immediate attention.

The Fix is In: How to Adjust and Maintain Your Outlaw 90 Chain

Preventative maintenance is the name of the game when it comes to keeping your Outlaw 90's chain in good condition. Here's a step-by-step guide to adjusting and maintaining the chain:

  1. Gather Your Tools: You'll need a wrench (usually 17mm or 19mm), a socket set, a chain lubricant, a rag, and potentially a chain breaker tool (if you need to remove links).
  2. Safety First: Park the ATV on a level surface, turn off the engine, and engage the parking brake.
  3. Locate the Chain Adjusters: On the Outlaw 90, these are typically located on the rear swingarm, near the rear axle. They usually consist of bolts that push the axle forward or backward to adjust chain tension.
  4. Loosen the Axle Nut: Before you can adjust the chain, you need to loosen the rear axle nut. Don't remove it completely, just loosen it enough to allow the axle to move.
  5. Adjust Chain Tension: Use the chain adjuster bolts to move the axle forward or backward. The goal is to achieve the correct chain slack. Refer to your owner's manual for the recommended slack measurement (usually around 1/2 to 3/4 of an inch of vertical movement in the middle of the chain). Make sure both adjusters are tightened equally to keep the rear wheel aligned.
  6. Check Wheel Alignment: After adjusting the chain, double-check that the rear wheel is properly aligned. Most Outlaw 90s have alignment marks on the swingarm to help with this. Proper alignment is crucial to prevent uneven chain wear.
  7. Tighten the Axle Nut: Once the chain tension and wheel alignment are correct, tighten the rear axle nut to the manufacturer's specified torque.
  8. Lubricate the Chain: Apply a high-quality chain lubricant to the entire length of the chain. Rotate the rear wheel to ensure the lubricant penetrates all the links.
  9. Clean the Chain: Regularly clean the chain with a chain cleaner or kerosene to remove dirt and grime. After cleaning, re-lubricate the chain.
  10. Inspect Regularly: Make it a habit to inspect the chain before and after each ride. Look for signs of wear, damage, or excessive slack.

When to Say Goodbye: Knowing When to Replace Your Chain

Even with meticulous maintenance, chains eventually wear out and need to be replaced. Here are some telltale signs that it's time for a new chain:

  • Excessive Stretching: If you've adjusted the chain to its maximum limit and it's still too loose, it's time for a new one.
  • Significant Wear: If the chain rollers are visibly worn, flattened, or damaged, it's time for a replacement.
  • Stiff Links That Won't Loosen: If you've tried lubricating the chain and some links remain stubbornly stiff, it's a sign of internal damage.
  • Chain is Elongated Beyond Serviceable Limits: Most chains have a wear indicator. If the chain has elongated beyond the specified limit, replace it immediately.

Don't wait until the chain breaks to replace it. A broken chain can cause serious damage to the ATV and potentially injure the rider. When replacing the chain, it's also a good idea to inspect the sprockets and replace them if they're worn. Replacing the chain without replacing worn sprockets is like putting new tires on a car with bad alignment – you're not addressing the underlying problem.

Choosing the Right Chain: Quality Matters

When it comes to replacing your Outlaw 90's chain, don't skimp on quality. A cheap chain might save you a few bucks upfront, but it will likely wear out much faster and could even break, causing damage. Look for a chain from a reputable brand that's specifically designed for ATVs. Consider an O-ring or X-ring chain, which has seals between the links to keep lubricant in and dirt out. These chains are more expensive, but they offer significantly longer life and require less maintenance.

Pro Tips for Outlaw 90 Chain Longevity

  • Teach Proper Riding Techniques: Encourage your child to ride smoothly and avoid excessive wheel spin.
  • Regular Cleaning and Lubrication: Make chain maintenance a part of your regular ATV maintenance routine.
  • Proper Chain Tension: Always ensure the chain is properly adjusted.
  • Inspect Sprockets Regularly: Replace worn sprockets along with the chain.
  • Use Quality Lubricants: Invest in a good chain lubricant that's designed for off-road use.
  • Avoid Harsh Chemicals: Don't use harsh chemicals or solvents to clean the chain, as they can damage the O-rings or X-rings.
  • Store the ATV Properly: When storing the ATV for extended periods, lubricate the chain thoroughly to prevent rust and corrosion.

Frequently Asked Questions

Q: How often should I lubricate my Outlaw 90 chain? A: Lubricate the chain after every ride, especially if you've been riding in wet or muddy conditions. A good rule of thumb is to lubricate every 1-2 hours of riding time.

Q: How tight should my Outlaw 90 chain be? A: Refer to your owner's manual for the specific chain slack measurement, but generally, you should have about 1/2 to 3/4 of an inch of vertical movement in the middle of the chain.

Q: What kind of lubricant should I use on my Outlaw 90 chain? A: Use a chain lubricant specifically designed for off-road motorcycles or ATVs. These lubricants are formulated to resist water and dirt.

Q: Can I just tighten the chain if it's loose? A: Yes, tightening the chain is the first step, but if the chain is excessively stretched or worn, tightening it won't solve the problem. You'll eventually need to replace it.

Q: How do I know if my sprockets are worn? A: Look for hooked or pointed teeth on the sprockets. If the teeth are significantly worn or damaged, it's time to replace them.

The Bottom Line

Chain problems on the Polaris Outlaw 90 are common, but they're also preventable. By understanding the causes of these issues and following a regular maintenance schedule, you can keep your young rider safely on the trail and avoid costly repairs. Regular cleaning, proper lubrication, and timely chain replacement are key to maximizing chain life and ensuring a fun and trouble-free riding experience.