Polaris PREDATOR 50 2009 Manual
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Polaris PREDATOR 50 2009 Manual

Polaris PREDATOR 50 2009 Manual

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MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2009 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2009 OUTLAW 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2009 SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2009 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2009 OUTLAW / SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MISCELLANEOUS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS - WHERE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
GENERAL INFORMATION
GENERAL INFORMATION
CHAPTER 1
1
1.1

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  • Page 1: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION MODEL INFORMATION ..........1.2 MODEL IDENTIFICATION .

  • Page 2: Model Information

    GENERAL INFORMATION MODEL INFORMATION Model Identification The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification 0 9 K A 0 9 AB Emissions & Year Designation Model Option Basic Chassis Engine Designation Designation Engine Designation Numbers 50cc Model: M10A - Single Cylinder, Air Cooled, SOHC, 4-Stroke, Electric Start...

  • Page 3: General Specifications

    GENERAL INFORMATION GENERAL SPECIFICATIONS MODEL.....2009 PREDATOR 50 MODEL NUMBER.....A09KA05AB, AD ENGINE MODEL....M10A Category Dimension Length 48 in. / 122 cm Width 31.5 in. / 80 cm Height 28 in. / 71 cm Wheel Base 33 in. / 84 cm Ground Clearance 4 in.

  • Page 4: Model: 2009 Predator 50

    3 in. / 7.6 cm Lubrication Oil Pump Pressurized Wet Sump Ground Clearance 4 in. / 10 cm ° Polaris SAE 40 (Above 32 ° Oil Requirements Polaris 20W-40 (Below 32 Shock Preload Adjustment Rear - Cam Adjust 30 oz. (900 ml) Toe Out 1/8 in.

  • Page 5: Model: 2009 Outlaw / Sportsman 90

    Ground Clearance 4 in. / 10 cm Lubrication Oil Pump Pressurized Wet Sump ° Front - Cam Adjust Polaris SAE 40 (Above 32 Shock Preload Adjustment ° Oil Requirements Rear - Cam Adjust Polaris 20W-40 (Below 32 30 oz. (900 ml) Toe Out 1/8 in.

  • Page 6: Miscellaneous Information

    Cloud Silver P-385 Replacement Keys Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the original. Should both keys become lost, ignition switch replacement is required. Key Blank...

  • Page 7: Special Tools - Where Used

    Special Tools may be required to service this ATV. Some of the tools listed are mandatory, while other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.

  • Page 8: Standard Torque Specifications

    GENERAL INFORMATION Standard Torque Specifications The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

  • Page 9: Conversion Table

    GENERAL INFORMATION Conversion Table Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft. lbs. kg-m x 7.233 = ft.

  • Page 10: Sae Tap Drill Sizes

    GENERAL INFORMATION SAE Tap Drill Sizes Decimal Equivalents Thread Size / Drill Size Thread Size / Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16...

  • Page 11: Glossary Of Terms

    CC: Cubic centimeters. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8" or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
  • Page 12 GENERAL INFORMATION NOTES 1.12...
  • Page 13 50 - 300 HOUR MAINTENANCE INTERVAL ........2.5 POLARIS LUBRICANTS AND SERVICE PRODUCTS ......2.6 MAINTENANCE REFERENCES .
  • Page 14 MAINTENANCE ELECTRICAL AND IGNITION SYSTEM ........2.21 BATTERY MAINTENANCE SERVICE NOTES .

  • Page 15: Periodic Maintenance Chart

    Polaris dealer. = SEVERE USE ITEM -- See Above E = Emission Control System Service (California). NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked with a could result in component failure and lead to serious injury or death.

  • Page 16: Pre-Ride - 40 Hour Maintenance Interval

    Oil Pre-Filter Screen 40 H 12 M 400 (640) if ATV is operated less than 10 hours Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 17: 50 - 300 Hour Maintenance Interval

    36 M 3000 (4800) Clean out Inspect periodically; adjust when parts are Toe Adjustment replaced Perform these procedures more often for vehicles subjected to severe use. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services.

  • Page 18: Polaris Lubricants And Service Products

    Loctite 518 Gasket Eliminator / Flange Transmission Lubricant 2871557 Sealant (50 ml.) (10 Count) 2873602 Polaris (AGL) ATV Gearcase Lubricant (qt.) 2871326 Premium Carbon Clean (12 oz.) (12 Count) Grease / Specialized Lubricants 2870652 Fuel Stabilizer (16 oz.) (12 Count)

  • Page 19: Maintenance References

    More often in severe use * More often under severe use, such as operated in water or under severe loads. **Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or Mobilegrease Special.

  • Page 20: General Vehicle Inspection And Maintenance

    MAINTENANCE GENERAL VEHICLE INSPECTION • Throttle - check for free operation AND MAINTENANCE • Headlight / Taillight / Brake light - check operation of all indicator lights and switches Pre-Ride / Daily Inspection • Engine stop switch - check for proper function Perform the following pre-ride inspection daily, and when •...

  • Page 21: Frame, Nuts, Bolts And Fastener Inspection

    MAINTENANCE Frame, Nuts, Bolts and Fastener Inspection Kick-Start Lever and Operation Periodically inspect the torque of all fasteners in accordance If the battery becomes too weak to start the engine, use the kick- with the maintenance schedule. Check that all cotter pins are in start lever to start the engine until the battery is serviced.

  • Page 22: Fuel System And Air Intake

    Adjustment adjust any speed limiting devices. Youth model Polaris ATVs have an adjustable throttle limiting screw. Speed limiting devices may be adjusted/removed only 1/16” - 1/8” by consumers when they determine that their child is capable (1.5 - 3.2 mm)

  • Page 23: Etc Operation

    MAINTENANCE ETC Operation ETC Switch Adjustment When the throttle is closed (idle) the throttle arm depresses a Slide the boot off the throttle cable adjuster and jam nut. small micro switch that limits engine rpm. Throttle Arm Micro Switch Switch Set parking brake.

  • Page 24: Choke Cable Adjustment

    MAINTENANCE Choke Cable Adjustment Idle Speed Adjustment Verify free play of 1/16-3/16” (1.6-4.76 mm) and smooth Start engine and warm it up thoroughly. operation of choke cable. Adjust idle speed by turning the slide adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM.

  • Page 25: Pilot Air Screw Adjustment

    MAINTENANCE Pilot Air Screw Adjustment Vent Lines Check fuel tank, crankcase, carburetor, battery and CAUTION transmission vent lines for signs of wear, deterioration, damage or leakage. Replace every two years. The pilot air screw is calibrated at the factory to Verify vent lines are routed properly and secured with meet EPA / CARB regulations for air quality cable ties.

  • Page 26: Fuel Valve Location

    MAINTENANCE Fuel Valve Location Sportsman 90 Predator 50 / Outlaw 90 Sportsman 90 Fuel Valve LH side of ATV Predator 50 Fuel Valve Turn knob to operate the fuel valve Outlaw 90 Fuel Valve Carburetor Draining The carburetor float bowl should be drained periodically to remove accumulated moisture or sediment from the bowl, or before extended periods of storage.

  • Page 27: Air Filter Service

    MAINTENANCE Air Filter Service Reinstall the screen, foam filter and air box cover. Secure the clips. Remove the seat. Reinstall the seat. Release the air box cover spring clips and remove the cover. Air Box Sediment Tube Clips Periodically check the air box sediment tube located toward the rear of the machine.

  • Page 28: Engine

    MAINTENANCE ENGINE Engine Oil and Filter Change Position the vehicle on a level surface. Engine Oil Level Clean area around the drain plug. Maintain the oil level within the safe range on the dipstick. Do not overfill. Run engine two to three minutes until warm. To check the oil level: Stop the engine.

  • Page 29: Compression / Leakdown Test

    Crankcase Drain Plug: 11 ft. lbs. (15 Nm) Intake Shown 11. Remove the dipstick. Add 30 oz. (900 ml) of recommended oil. Do not overfill. Recommended Engine Oil: Polaris Synthetic Youth 4-Stroke Oil SAE 40 (Above 32°F) Quart - (PN 2876248) Gallon - (PN2876249) Polaris Semi-Synthetic Oil 20W-40 (Below 32°F)

  • Page 30: Engine Mounts

    MAINTENANCE Engine Mounts Exhaust Spark Arrestor Cleaning Inspect engine mounts for cracks or damage. WARNING Engine Fastener Torque Do not perform clean out immediately after the Check engine fasteners and ensure they are tight engine has been run, as the exhaust system CVT Drying (90cc Models) becomes very hot.

  • Page 31: Transmission And Final Drive

    Reinstall the fill plug. TRANSMISSION SPECIFICATIONS Transmission Lubricant Change Recommended Lubricant: Position the vehicle on a level surface. Polaris (AGL) ATV Gearcase Lubricant: Remove the fill plug. Quart - (PN 2873602) Place a drain pan beneath the transmission. Capacity: Remove the drain plug and allow the lubricant to drain 11.8 oz.

  • Page 32: Drive Chain Inspection - 90Cc Models

    Transmission Drain Plug: 14 ft. lbs. (19 Nm) Add the recommended lubricant. Maintain the lubricant level at the bottom of the fill plug hole threads. Reinstall the fill plug. Check for leaks. Polaris (AGL) ATV Gearcase Lubricant: 1/4”-1/2” (6-12 mm) 11.8 oz. (350 ml) Deflection or bottom of transmission fill hole threads The chain should have 1/4”-1/2”...

  • Page 33: Sprocket Inspection

    MAINTENANCE ELECTRICAL AND IGNITION SYSTEM Tighten the chain adjuster lock nut to 84 in. lbs. (9.4 Nm) and re-verify the chain tension is at specification. Battery Maintenance Service Notes WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

  • Page 34: Battery Removal - 50Cc

    MAINTENANCE Battery Removal - 50cc Battery Removal - 90cc WARNING WARNING Improperly connecting or disconnecting battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious cables can result in an explosion and cause serious injury or death. When removing the battery, always injury or death.

  • Page 35: Battery Installation

    MAINTENANCE Battery Installation Spark Plug Inspection Place the fully charged battery in its holder. Remove spark plug high tension lead. Clean plug area so no dirt and debris can fall into engine when plug is Attach the hold-down strap(s). removed. Connect and tighten the red positive (+) cable first.

  • Page 36: Ignition Timing

    WARNING Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component repair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace worn or damaged steering parts.

  • Page 37: Tie Rod End / Steering Inspection

    All tie rod adjustments should be performed Remove the front wheels. by an authorized Polaris dealer. Grasp the steering tie rod and pull in all directions feeling Use the following procedure to check the toe alignment of the for movement in the tie rod end.

  • Page 38: Toe Adjustment

    MAINTENANCE Measure the distance from the string to the rim at the front • Shorten or lengthen the tie rod until alignment is as and rear of the front rim. Rear measurement should be required to achieve the proper toe setting - (1/8” to 1/ 1/16”...

  • Page 39: Suspension Spring Adjustment

    MAINTENANCE BRAKE SYSTEM • Inspect shock for leakage. Brake System Inspection The following checks are recommended to keep the brake system in good operating condition. Service life of brake system Preload components depends on operating conditions. Inspect brakes in Adjuster accordance with the maintenance schedule and before each ride.

  • Page 40: Brake Freeplay

    MAINTENANCE Brake Freeplay While rotating the left front wheel, tighten the upper front brake adjuster nut on the right-hand control. Measure the free-play of the front and rear brakes at the intervals recommended in the Periodic Maintenance Chart. If the freeplay isn’t at specification, adjust the freeplay as outlined below.

  • Page 41: Rear Brake Adjustment

    MAINTENANCE Rear Brake Adjustment Brake Shoe Inspection Position the vehicle on a level surface. Brake shoes should be changed when friction material is worn to service limit. See Chapter 6 (Brakes) for specifications. Shift the transmission into neutral (if applicable). Brake Shoes Elevate the rear of the vehicle by placing a suitable stand under the frame.

  • Page 42: Wheel Removal - Front / Rear

    MAINTENANCE Wheel Removal - Front / Rear Tire Pressure Stop the engine, place the transmission in gear and lock the Tire Pressure Inspection (PSI - Cold) parking brake. MODEL FRONT / REAR Loosen the wheel bolts slightly. Sportsman 90 3 psi / 3 psi (20.7 kPa) Elevate the side of the vehicle by placing a suitable stand Outlaw 90 3 psi / 3 psi (20.7 kPa)
  • Page 43 ENGINE / TRANSMISSION CHAPTER 3 ENGINE / TRANSMISSION ENGINE SERVICE ............3.3 ENGINE EXPLODED VIEWS &...
  • Page 44 ENGINE / TRANSMISSION ENGINE ASSEMBLY........... . 3.28 CRANKCASE ASSEMBLY .

  • Page 45: Engine Service

    ENGINE / TRANSMISSION ENGINE SERVICE Engine Exploded Views & Torque Values CRANKCASE 87 lb-in. (10 Nm) Replace all gaskets, O-rings Torque all in 2 steps using and seals upon assembly a cross pattern 87 lb-in. (10 Nm) 6x60 43 lb-in. (5 Nm) 5x16 14.5 lb-ft.

  • Page 46: Engine Exploded Views & Torque Values

    ENGINE / TRANSMISSION Engine Exploded Views & Torque Values CYLINDER / CRANKSHAFT / PISTON Replace all gaskets, O-rings and seals upon assembly “IN” 87 lb-in. (10 Nm) 104 lb-in. (12 Nm) CAMSHAFT CHAIN / ROCKER ARM 87 lb-in. (10 Nm) Replace all gaskets, O-rings and seals upon assembly 87 lb-in.

  • Page 47: Engine Exploded Views & Torque Values

    ENGINE / TRANSMISSION Engine Exploded Views & Torque Values TRANSMISSION 87 lb-in. (10 Nm) Bearing, Sealed Torque all in 2 steps using a cross pattern 87 lb-in. (10 Nm) 6x40mm 87 lb-in. (10 Nm) Replace all gaskets, O-rings and seals upon assembly Snap Ring Forward Sliding Gear...

  • Page 48: Special Tools

    ENGINE / TRANSMISSION Special Tools PART NUMBER TOOL DESCRIPTION 2200634 Valve Seat Reconditioning Kit 2870390 Piston Support Block PA-45153 Flywheel Puller PA-46502 Valve Spring Compressor Adaptor, Valve Spring PA-48701 Compressor Engine Service Data Predator 50 Cylinder Head / Valvetrain Rocker arm ID (In/Ex) .3937 - .3944"...
  • Page 49 ENGINE / TRANSMISSION Engine Service Data Cylinder / Piston / Connecting Rod Predator 50 Surface warpage limit (mating with cylinder head) .002" (.05 mm) Cylinder bore 1.5354 - 1.5358" (39.00 - 39.01 mm) Taper limit .002" (.05 mm) Cylinder Out of round limit .002"...

  • Page 50: Engine Service Data

    ENGINE / TRANSMISSION Engine Service Data Sportsman 90 / Outlaw 90 Cylinder Head / Valvetrain Rocker arm ID (In/Ex) .3937 - .3944" (10.00-10.02 mm) Rocker Arm Rocker arm ID (In/Ex) Limit .3976" (10.10 mm) Rocker arm shaft OD (In/Ex) .3926 - .3932" (9.97 - 9.99 mm) Rocker Arm Shaft Rocker arm shaft OD (In/Ex)
  • Page 51 ENGINE / TRANSMISSION Engine Service Data Cylinder / Piston / Connecting Rod Sportsman 90 / Outlaw 90 Surface warpage limit (mating with cylinder head) .002" (0.05 mm) Cylinder bore 1.8504 - 1.8507" (47.00 - 47.01 mm) Taper limit .002" (0.05 mm) Cylinder Out of round limit .002"...

  • Page 52: Oil Flow Diagram

    ENGINE / TRANSMISSION Oil Flow Diagram Valve Rocker Rocker Adjusters Arm Shaft Arms Camshaft RH Camshaft Cover Connecting Cylinder Wall Oil Passage Rod (Small End) Chains & Sprockets RH Lower LH Cam- Crank Pin and Cylinder Stud shaft Connecting Cover (Through Cylinder Rod (Big End) Head)

  • Page 53: Piston / Ring Identification

    ENGINE / TRANSMISSION Piston / Ring Identification Engine Removal The letters “IN” or the larger of two valve pockets on the piston Clean the ATV and work area thoroughly. face the intake side of the engine (UP). Other numbers may be Remove seat.

  • Page 54: Engine Installation Notes

    ENGINE / TRANSMISSION Engine Installation Notes Cover any openings with a clean shop towel. Disconnect or Remove From LEFT Side: After the engine is installed in the frame, review this checklist and perform all steps that apply: • CVT Air Ducts General Items •...

  • Page 55: Engine Lubrication

    Top Dead Center (TDC) is referenced throughout this section. Oil Type:** Above 32°F Properly locate TDC on compression stroke prior to: Polaris Synthetic Youth 4-Stroke Oil (40 W) • Top end disassembly or assembly Quart - (PN 2876248) Gallon - (PN2876249) •...

  • Page 56: Top-End Disassembly

    ENGINE / TRANSMISSION Cam Chain Tensioner Removal USE THE FLYWHEEL TIMING MARK Remove timing hole plug from flywheel cover. NOTE: Tensioner can be removed with engine in frame. Rotate the engine in normal direction of rotation and watch the intake valve open and then close. Find TDC on compression stroke.

  • Page 57: Cylinder Head Removal

    ENGINE / TRANSMISSION Cylinder Head Removal Rocker Arm Disassembly / Inspection NOTE: Cylinder head must be removed to service REMOVE: the rocker arms. Bolt (A). NOTE: Mark or tag rocker arms and shafts to keep Nuts (B) evenly in a cross pattern until loose. them in order for assembly.

  • Page 58: Camshaft Removal

    ENGINE / TRANSMISSION Camshaft Inspection Measure O.D. of rocker shaft in 3 places (E). Measure I.D. of rocker arm (F) and compare to Inspect cam sprocket teeth for wear or damage. specification. Inspect rocker adjuster screws (G) and the end of the valve stems for wear, pitting, or damage to threads of the adjuster or locknut.

  • Page 59: Cylinder Head Inspection

    ENGINE / TRANSMISSION Cylinder Head Inspection Cylinder Head Disassembly Thoroughly clean cylinder head surface to remove all WARNING traces of gasket material and carbon. CAUTION Wear eye protection or a face shield during cylinder head disassembly and reassembly. Use care not to damage sealing surface. If there NOTE: Keep all parts in order with respect to their is damage found on the cylinder head location in the cylinder head.

  • Page 60: Valve Inspection

    ENGINE / TRANSMISSION Valve Inspection Measure free length of the inner and outer springs with a Vernier caliper, Ill.1. Check spring for squareness as Remove all carbon from valve with a soft wire wheel. shown in Ill.2. Replace spring if measurements are out of specification.

  • Page 61: Valve Seat Reconditioning

    ENGINE / TRANSMISSION Valve Seat Reconditioning Install the valve in its mating guide and lift it 5mm off of the seat. Push valve back and forth and measure deflection Valve Seat Inspection in two directions. If deflection exceeds limit repeat test with a new valve, or measure stem to guide clearance as outlined Inspect valve seat in cylinder head for pitting, burnt spots, in Step 6 and 7 to determine if wear is in the guide or the...
  • Page 62 ENGINE / TRANSMISSION Install pilot into valve guide. Remove valve and check where the paste or black marker indicates seat contact on the valve face. The valve seat should contact the middle of the valve face or slightly above, and must be the proper width (A). Proper Seat Contact On Valve Face Apply cutting oil to valve seat and cutter.

  • Page 63: Cylinder Head Assembly

    ENGINE / TRANSMISSION Cylinder Head Assembly NOTE: When using an interference angle, the seat contact point on the valve will be very narrow, and is a normal condition. Look for an even and CAUTION continuous contact point on the black marker, all the way around the valve face.

  • Page 64: Valve Sealing Test

    ENGINE / TRANSMISSION Valve Sealing Test Cam Chain Tensioner Blade To remove the tensioner blade (C), remove PVT cover and Clean and dry the combustion chamber area. drive clutch (refer to PVT Section). NOTE: Tensioner blade removal is only required for service Pour a small amount of clean solvent into each port and of the blade.

  • Page 65: Cylinder Inspection

    Using a common spring loaded glaze breaker for honing is not advised. Polaris recommends using a rigid hone or arbor honing machine. Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations.

  • Page 66: Piston Inspection

    ENGINE / TRANSMISSION Piston Inspection Measure connecting rod small end ID. Replace crankshaft if connecting rod small end is out-of-round. NOTE: refer to specifications at the beginning of this chapter as required. Measure piston outside diameter at a point 3mm up from bottom of piston at a right angle to direction of piston pin.

  • Page 67: Piston Ring Installed Gap

    ENGINE / TRANSMISSION Piston Ring Installed Gap BOTTOM-END DISASSEMBLY Place each piston ring inside cylinder using piston to push Flywheel Removal / Inspection ring squarely into place as shown. Remove the flywheel cover, the flywheel nut, and washer. Piston ring end gap installed Install flywheel puller and remove flywheel.

  • Page 68: Oil Pump Removal

    ENGINE / TRANSMISSION Oil Pump Removal Remove body screw and plate. NOTE: Oil pump is not a serviceable assembly. NOTE: The CVT system, starter motor, starter drive, flywheel, stator, oil pump and transmission can be serviced with the engine in the frame. Remove stator.

  • Page 69: Crankcase Disassembly

    ENGINE / TRANSMISSION Crankcase Disassembly Crankshaft / Cam Chain / Sprocket Inspection NOTE: Engine must removed perform crankcase or crankshaft service. Inspect the crankshaft main bearings and cam chain sprocket for wear or damage. NOTE: The CVT system, starter motor, starter drive, NOTE: Due to extremely close tolerances and flywheel, stator, oil pump and transmission can be minimal wear, the bearings must be inspected...

  • Page 70: Crankcase Oil Strainer Inspection

    ENGINE / TRANSMISSION Crankcase Oil Strainer Inspection Install case screws. Torque in two steps to specification following sequence shown. Remove strainer plug. Crankcase Screw Torque: Remove oil strainer and visually inspect for any rips, tears or obstructions in screen. 87 in. lbs. (10 Nm) Replace oil strainer if it fails visual inspection.

  • Page 71: Piston Installation

    ENGINE / TRANSMISSION Piston Installation Tensioner Blade Installation Install tensioner blade and tighten mounting bolt to CAUTION specified torque (arrow). Do not re-use circlips. Circlips become deformed during the removal process. Do not compress the new clip more than necessary to prevent loss of radial tension.

  • Page 72: Cylinder Head & Camshaft Installation

    ENGINE / TRANSMISSION Install cam chain guide. Pull cam chain tight so blade will Install cam chain sprocket to chain with dot on sprocket at slide into notch in crankcase. the top. Sprocket must be timed before cylinder head is installed.

  • Page 73: Cam Chain Tensioner Installation

    ENGINE / TRANSMISSION Install two cylinder base bolts (C) with carburetor drain With the plunger retracted, install the tensioner assembly hose guide on lower bolt. and tighten the bolts to specification. Install cylinder head bolt (D. Install four head nuts (E) with new sealing washers. Tensioner Body Bolt Torque: Torque cylinder head and bolts in two steps to specification, 5-6.5 ft.

  • Page 74: Transmission

    ENGINE / TRANSMISSION TRANSMISSION Slowly rotate engine 2-3 revolutions in normal direction of rotation. Rotate to TDC on compression stroke and verify Transmission Disassembly and Inspection camshaft timing is correct. NOTE: Engine removal required service transmission components. Process shown below is with engine removed for clarity.
  • Page 75 ENGINE / TRANSMISSION Remove the cover screws. Remove the shift shaft by pulling straight outward. DO NOT LOSE the spring and plunger (G) on the inner end of the shaft. This plunger contacts the gear position switch. Remove cover with output shaft. Push or tap on shift shaft 10.
  • Page 76 ENGINE / TRANSMISSION 12. Remove the counter shaft. 15. Loosen the 12mm hex bolt and remove the shift detent ball and spring assembly. 13. Remove shift drum. Push detent ball located at (I) back against spring pressure to ease removal. 14.

  • Page 77: Transmission Inspection

    ENGINE / TRANSMISSION Transmission Inspection Inspect sliding gear dogs and dog slots in the mating gears (F) for wear or damage. The edges of dogs and slots should NOTE: Always wear the appropriate protective gear and use be square and not rounded. Replace both sliding gear and caution when operating a press.
  • Page 78 ENGINE / TRANSMISSION Shaft Disassembly Shaft Assembly 11. Assemble the reverse gear (90cc), washer, a new snap ring, If radial movement in Step 7 was excessive, support the and the sliding gear on the shaft. forward gear and press the shaft through the spacer to disassemble it from the shaft.

  • Page 79: Transmission Assembly

    ENGINE / TRANSMISSION Transmission Assembly 87 in. lbs. (10 Nm) 87 in. lbs. (10 Nm) 25 ft. lbs. (34 Nm) IMPORTANT: To reassemble the transmission, reverse Check transmission operation before final assembly, and the disassembly procedure, refer to exploded view, and after installing outer cover and output shaft.
  • Page 80 ENGINE / TRANSMISSION Assemble the detent ball and spring with transmission lubricant. Tighten bolt to specification. Shift Detent Hex Bolt Torque 25 ft. lbs. (34 Nm) Install the transmission cover and new gasket. Install the eight (8) retaining bolts and torque in two steps to specification following the sequence shown.

  • Page 81: Starter Drive Mechanism (Electric)

    ENGINE / TRANSMISSION Starter Drive Mechanism (Electric) Remove thrust washer from shaft. Remove CVT cover. See “Clutch Cover Removal” in Chapter 7. Remove drive clutch. Before removing the starter one-way clutch / gear assembly, inspect the gear operation. The ring gear should rotate smoothly and freely in a clockwise direction (A).
  • Page 82 ENGINE / TRANSMISSION Lift the gear off of the one-way clutch. Note the washer 11. Assemble the springs, plungers, and rollers into the hub. inside the hub (A). This washer must be centered upon Push each roller (E) back toward plunger and spring, and assembly.

  • Page 83: Kick Start

    ENGINE / TRANSMISSION KICK START Disconnect hooked end of spring and set against stop at (B). Kick Start Disassembly / Inspection CAUTION The kick start spring is under tension. Wear face protection during disassembly and assembly of the kick start mechanism. NOTE: It is not necessary to remove the kick start lever or kick drive components to remove the engine cover.

  • Page 84: Kick Start Assembly

    ENGINE / TRANSMISSION Kick Start Assembly Lift hooked end of spring over the stop and allow it to unwind completely (about another 180 degrees). Secure cover lightly in a vise as shown. Protect the surface of the cover from damage. Remove shaft with bushing (E), O-ring (F), and spring.
  • Page 85 ENGINE / TRANSMISSION Hold spring up against kick gear and rotate gear Install kick start pedal, aligning marks made previously. counterclockwise until trailing edge (E) is past the stop (F). Push gear down until seated and then release gear to rest against the stop.

  • Page 86: Troubleshooting

    ENGINE / TRANSMISSION TROUBLESHOOTING Engine (General) Engine Turns Over But Fails to Start Spark Plug Fouling • No fuel • Spark plug cap loose or faulty • Dirt in fuel line or filter • Choke cable adjustment, cable or shaft sticking •...
  • Page 87 ENGINE / TRANSMISSION Engine Idles But RPM Will Not Increase Low Compression • Spark plug fouled/weak spark • Cylinder head gasket leak • Broken throttle cable • No valve clearance or incorrectly adjusted • Obstruction in air intake • Cylinder or piston worn •...
  • Page 88 ENGINE / TRANSMISSION Transmission Gear Will Not Engage • Shift arm indexed incorrectly (hits bracket) • Shift arm slipping on spline • CVT Belt broken • Internal trans gear damage • Shift fork broken or bent • Shift shaft broken Pops Out Of Gear •...
  • Page 89 FUEL SYSTEM CHAPTER 4 FUEL SYSTEM CARBURETION SYSTEM ..........4.2 SPECIAL TOOLS .

  • Page 90: Carburetion System

    FUEL SYSTEM CARBURETION SYSTEM Carburetor Function Special Tools Carburetor Component Function Main Main Main System Components Function Affect PART NUMBER TOOL DESCRIPTION ™ Mity Vac Maintains specified 2870975 Inlet Pipe, Needle fuel level in float Pressure Test Tool Float System All systems;...

  • Page 91: Carburetion Specifications

    FUEL SYSTEM Carburetion Specifications CARBURETOR OPERATION Operation Overview PREDATOR 50 The engine of a vehicle is operated under a wide range of Cutaway conditions, from idling with the throttle valve remaining almost closed, to full load or maximum output with the throttle valve Pilot Air Screw 2.5 turns out fully opened.

  • Page 92: Float System

    FUEL SYSTEM Float System Pilot Mixture Screw The float system is designed to maintain a constant height of The pilot mixture screw controls the fuel mixture from idle to gasoline during operation. When the fuel flowing from the fuel low speeds. The tapered tip of the mixture screw projects into pump into the float chamber through the needle valve reaches the fuel mixture passage leading to the pilot jet air bleeds.

  • Page 93: Air / Fuel Mixture Ratio

    FUEL SYSTEM Air / Fuel Mixture Ratio Jet Needle The jet needle has five adjustment grooves cut into the upper E-Clip Position vs. Fuel Flow portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end extends into the needle jet.

  • Page 94: Throttle Opening Vs. Fuel Flow

    FUEL SYSTEM Throttle Opening vs. Fuel Flow Main Jet In a full throttle condition the cross sectioned area between the When the throttle opening becomes greater and the area between jet needle and the needle jet is larger than the cross sectioned the needle jet and jet needle increases, fuel flow is metered by area of the main jet.

  • Page 95: Pilot System (Idle - 3/8 Throttle)

    FUEL SYSTEM Pilot System (Idle - 3/8 Throttle) Slide Cutaway (1/8 - 3/8 Throttle) The pilot system’s main function is to meter fuel at idle and low Throttle valve cutaway effect is most noticeable at 1/4 throttle speed driving. Though its main function is to supply fuel at low opening.

  • Page 96: Jet Needle / Needle Jet (3/8 - 3/4 Throttle)

    FUEL SYSTEM Jet Needle / Needle Jet (3/8 - 3/4 Throttle) Main System (3/4 to Full Throttle) The jet needle and needle jet have the most effect between 3/8 The main system is designed for delivering fuel between low and 3/4 throttle opening. Some mixture adjustment can be speed and high speed operation.

  • Page 97: Fuel Delivery

    FUEL SYSTEM Fuel Delivery CARBURETOR SERVICE The throttle opening chart below demonstrates component Carburetor Float Bowl Draining relationship to fuel flow versus throttle valve opening. The carburetor float bowl should be drained periodically to The pilot system’s main function is that of a low speed jet. Its remove moisture or sediment from the bowl, or before extended most effective range of fuel delivery is from idle to periods of storage.

  • Page 98: Carburetor Removal - General

    FUEL SYSTEM Carburetor Removal - General Carburetor Disassembly - 50cc (Mikuni) The following procedure is provided to use as a reference when Use the following procedure to disassemble the Mikuni removing the carburetor from either of the 4-stroke youth carburetor used on the 50cc models. models.

  • Page 99: Carburetor Disassembly - 90Cc (Keihin)

    FUEL SYSTEM Carburetor Disassembly - 90cc (Keihin) Remove the pilot jet (L), main jet (M), and emulsion tube (N) from the carb body. Use the following procedure to disassemble the Keihin carburetor used on 90cc models. Remove the (2) float bowl screws and float bowl (A). Note the position of both the pilot mixture screw (P) and idle speed adjustment screw (Q) and remove both from the carb body.

  • Page 100: Carburetor Cleaning

    FUEL SYSTEM Carburetor Cleaning Remove the main jet (F), emulsion tube (G), and needle jet (H) from the carburetor body. WARNING Protect eyes from contact with cleaner. Take appropriate safety measures during these procedures. Safety glasses and chemical resistant gloves are required. Should you get cleaner in your eyes or if you swallow cleaner, seek medical attention immediately.

  • Page 101: Carburetor Inspection

    FUEL SYSTEM Carburetor Inspection Inspect the idle speed adjust screw tip for flat spots and the pilot mixture screw tip for damage. If any damage is Remove the carburetor slide assembly. Disassemble the present on either screw, it must be replaced. components and inspect for wear.

  • Page 102: Float Height Adjustment

    FUEL SYSTEM Float Height Adjustment Carburetor Assembly Place the carburetor at a level position to remove weight Replace parts in proper order. Refer to the parts exploded from float arm. In this position, the float tongue will rest view or “Disassembly” steps for further detail slightly outward.

  • Page 103: Fuel Tank Exploded View

    FUEL SYSTEM FUEL TANK EXPLODED VIEW Outlaw 90 Model Shown 103 in. lbs. (12 Nm) Fuel Tank Assembly ESCRIPTION ESCRIPTION Cap, Fuel Clip Gasket, Fuel Cap Fuel Line, Carb Inlet Hose, Vent Fuel Filter Fuel Valve Screw Washer Fuel Line, Main Bolt Spacer Clamp...

  • Page 104: Fuel Tank Removal

    FUEL SYSTEM Fuel Tank Removal Fuel Valve Location Predator 50 / Outlaw 90 See Chapter 5 for body removal procedures to gain access the fuel tank. LH side of ATV Predator 50 Completely drain fuel from fuel tank. Be sure the fuel Fuel Valve valve is set to “RES”...

  • Page 105: Fuel Valve Service Predator 50 / Outlaw 90

    FUEL SYSTEM Fuel Valve Layout Sportsman 90 Predator 50 / Outlaw 90 Sportsman 90 Fuel Valve Fuel Outlet Reserve Line Main Line Turn knob to operate the fuel valve Sportsman 90 Main Line Fuel Outlet Fuel Valve Service Predator 50 / Outlaw 90 To service the fuel valve: Turn the fuel valve to “OFF”...

  • Page 106: Air Cleaner Exploded View

    FUEL SYSTEM AIR CLEANER EXPLODED VIEW 90cc Model Shown Opening towards rear of ATV Air Cleaner Assembly ESCRIPTION ESCRIPTION Clamp Box, Air Cleaner Boot Screen Filter Hose, Drain Foam Filter Clip Gasket Clip Cover, Air Cleaner 4.18...

  • Page 107: Troubleshooting

    FUEL SYSTEM TROUBLESHOOTING Poor Idle Idle Too High Fuel Starvation / Lean Mixture • Idle adjusted improperly / idle mixture screw damaged Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, • Throttle cable sticking, improperly adjusted, routed incorrectly spark plug erosion, engine runs hot, surging, high idle, idle speed erratic.
  • Page 108 FUEL SYSTEM NOTES 4.20...
  • Page 109 BODY / SUSPENSION / STEERING CHAPTER 5 BODY / SUSPENSION / STEERING GENERAL INFORMATION ..........5.2 SPECIAL TOOLS .

  • Page 110: General Information

    BODY / SUSPENSION / STEERING GENERAL INFORMATION BODY REMOVAL - PREDATOR 50 Special Tools Body Removal Lift up on the seat latch and remove the seat. Description Part Number Shock Spanner Wrench 2870872 Torque Specifications Fastener Torque Suspension Fasteners A–Arm Attaching Bolt 25 ft.

  • Page 111: Footwell Removal

    BODY / SUSPENSION / STEERING Remove or loosen the front body attachment bolts under the Unhook the running light harnesses and completely remove running lights. the front cover with the running lights attached. Remove the fuel tank cap and carefully remove the body Remove the screws attaching the front cover to the body.

  • Page 112: Front Bumper Removal / Installation

    BODY / SUSPENSION / STEERING Front Bumper Removal / Installation Remove the 6 screws and lift the removable footwell off. Remove the (4) mounting bolts retaining the front bumper and remove the bumper from the ATV. Remove the 4 screws attaching the main footwells to the frame on each side and remove the footwells.

  • Page 113: Body Removal - Outlaw 90

    BODY / SUSPENSION / STEERING BODY REMOVAL - OUTLAW 90 Remove the (3) fasteners on each side attaching the footwells to the rear cab. Rear Cab Removal Remove the rear cab from ATV. Lift up on the seat latch and remove the seat. Side Panel Removal Remove the seat.

  • Page 114: Front Cab Removal

    BODY / SUSPENSION / STEERING Front Cab Removal Remove the fuel tank cap to allow the tank cover to be removed if required. Remove the front cab cover by carefully lifting up on the cover to disengage the plastic tabs. Front Bumper Removal / Installation Remove the (2) screw inserts attaching the front cab to the fuel tank cover.

  • Page 115: Outlaw 90 - Body Exploded View

    BODY / SUSPENSION / STEERING Outlaw 90 - Body Exploded View 87 in. lbs. (9.8 Nm) 87 in. lbs. (9.8 Nm) 43 in. lbs. (4.9 Nm) 87 in. lbs. (9.8 Nm) 43 in. lbs. (4.9 Nm)

  • Page 116: Body Removal - Sportsman 90

    BODY / SUSPENSION / STEERING BODY REMOVAL - SPORTSMAN 90 Remove the (4) fasteners and (1) screw insert on each side attaching the footwells to the rear cab. Rear Cab Removal Disconnect the tail light and remove rear cab from the ATV. Lift up on the seat latch and remove the seat.

  • Page 117: Front Cab Removal

    BODY / SUSPENSION / STEERING Front Cab Removal Remove the (2) screw inserts attaching the front cab to the front cab cover under the handle bar pod. Remove the (3) bolts and (2) screws retaining the front bumper to the ATV. The (2) screws are on the backside of the front bumper and attach the bumper to the front cab.

  • Page 118: Bumper And Rack Removal

    BODY / SUSPENSION / STEERING Bumper and Rack Removal Rack Mounting Fasteners 87 in. lbs. (9.8 Nm) 87 in. lbs. 87 in. lbs. (9.8 Nm) (9.8 Nm) 87 in. lbs. 16 ft. lbs. (21.5 Nm) (9.8 Nm) 16 ft. lbs. (21.5 Nm) Sportsman 90 - Body Exploded View 87 in.

  • Page 119: Indicator Light / Ignition Switch Replacement

    BODY / SUSPENSION / STEERING Indicator Light / Ignition Switch Replacement SUSPENSION Remove the (3) screws retaining the upper portion of the pod. 50cc Shocks and Springs Front Shocks Rear Shock 25 ft. lbs. 36 ft. lbs. (34 Nm) (49 Nm) Disconnect the ignition switch harness and/or indicator 90cc Shocks and Springs light harnesses.

  • Page 120: Front Shock Removal

    BODY / SUSPENSION / STEERING Front Shock Removal Remove the upper shock mounting bolt from the frame and the lower shock mounting bolt from the swing arm. Elevate front end of the ATV off the ground to remove shock spring tension. Predator 50 Shown CAUTION...

  • Page 121: Control Arm Replacement

    BODY / SUSPENSION / STEERING Control Arm Replacement Remove the lower shock mounting fastener and inner control arm fastener. Elevate front end of ATV off the ground far enough to remove the wheel. CAUTION Severe injury could occur if machine tips or falls. Remove the dust cap and cotter pin.

  • Page 122: Front A-Arm - 90Cc

    BODY / SUSPENSION / STEERING FRONT A-ARM - 90CC A-arm Exploded View Upper Right A-arm Grease Fittings Spindle Bushing Grease Fittings Grease Fitting Lower Spindle Bushing Upper Bushings Spindle Bushing (8) Total Lower Spindle Bushing Right Spindle 25 ft. lbs. (34 Nm) Left A-arm Grease Fitting...

  • Page 123: Swing Arm

    BODY / SUSPENSION / STEERING SWING ARM Remove the lower shock mounting fastener and the inner A-arm fasteners. Removal Elevate rear end of ATV off the ground far enough to remove the rear wheel(s). CAUTION Severe injury could occur if machine tips or falls. Remove the dust cap and cotter pin from the LH rear wheel Remove LH rear wheel nut and remove wheel and hub as an assembly.
  • Page 124 BODY / SUSPENSION / STEERING Remove the rear brake cable adjuster nut and pull cable out Remove the (2) bolts retaining the inner brake housing to from swing arm bracket. the axle housing and slide inner housing off the axle. Remove the (2) bolts retaining the chain guard and remove Remove the (2) nuts and (2) bolts retaining the axle housing the guard.

  • Page 125: Steering - 50Cc

    BODY / SUSPENSION / STEERING STEERING - 50CC 12. 50cc - Remove the (2) through-bolts, exhaust mount bolt and lower shock mounting bolt from the swing arm and remove the swing arm from the ATV. Steering Assembly Exploded View 90cc - Remove the (1) through-bolt on 90cc models as shown in the second image below.

  • Page 126: Steering - 90Cc

    BODY / SUSPENSION / STEERING STEERING - 90CC Remove the inner tie-rod nuts and the steering post nut. Steering Post Nut Steering Assembly Exploded View 16 ft. lbs. 90cc Models (22 Nm) 25 ft. lbs. (34 Nm) 16 ft. lbs. (22 Nm) 16 ft.

  • Page 127: Tie Rod

    BODY / SUSPENSION / STEERING TIE ROD Remove the inner tie-rod nuts. Removal / Adjustment Tie Rod Nuts Steering tie rods can be replaced by removing the rod-end castle nut at the steering post and spindle. Tighten inner and outer tie rod bolts and jam nuts to specification Remove the steering post nut.

  • Page 128: Handlebar

    BODY / SUSPENSION / STEERING HANDLEBAR DECAL REPLACEMENT Predator 50 Exploded View WARNING Install the lower clamps. (circle) The following procedure involves the use of an 42 in. lbs. open flame. Perform this procedure in a well (4.7 Nm) ventilated area, away from gasoline or other 84 in.
  • Page 129 BRAKES CHAPTER 6 BRAKES SPECIFICATIONS ............6.2 GENERAL SPECIFICATIONS .

  • Page 130: Specifications

    BRAKES SPECIFICATIONS General Specifications Front Brake Drum Item Standard Service Limit Brake Shoe Thickness 0.10” (2.54 mm) 0.05” (1.27 mm) Brake Drum Inner Diameter 3.35" / (85.09 mm) 3.38" / (88.85 mm) Rear Brake Drum Item Standard Service Limit Brake Shoe Thickness 0.15”...

  • Page 131: Front Brakes

    BRAKES FRONT BRAKES Exploded View Brake Cables Brake Shoe Return Return Spring Spring RH Brake Arm LH Brake Arm 43 in. lbs. (4.9 Nm) Brake Shoe RH Plate Bolts Brake Cam Brake Cam LH Plate Front Brake Service Elevate front end of ATV off the ground far enough to Remove the outer bearing spacer from the wheel hub.
  • Page 132 BRAKES Brake Drum Backing Plate Removal Inspect the outer seal and outer bearing for wear or damage. If service is required to backing plate components, remove the cotter pin retaining the backing plate to the spindle. Bearing Cotter Pin Seal Flip the wheel hub and inspect the inner seal and inner bearing for wear or damage.
  • Page 133 BRAKES Brake Shoe Removal 13. Inspect the brake shoe pad material. Replace if worn beyond specification. 10. Reinstall brake backing plate and components if previously removed. 11. Using a suitable tool, lift up on the spring near the retainer stud as shown and remove the spring. Remove Here = In.
  • Page 134 BRAKES Brake Assembly 15. Use the illustration below as reference when reassembling the front brake components. 16. Inspect oil seals and bearings for wear or damage upon assembly. Replace bearings and seals if necessary. 17. Install the wheel hub and tighten the front spindle nut to specification.

  • Page 135: Rear Brake

    BRAKES REAR BRAKE Exploded View 16 ft. lbs. Brake Cable (22 Nm) Nuts Bolts Cable Spring Bolt 40 ft. lbs. Plate Spacer (54 Nm) Brake Arm Adjuster Nut Flange Nut Spring 43 in. lbs. 40 ft. lbs. (4.9 Nm) Brake (54 Nm) Bolt Oil Seal...
  • Page 136 BRAKES Inspect the protective rubber gasket for nicks or other Inspect the brake shoe pad material. Replace if worn damage. Replace if necessary. beyond specification. Rubber Gasket Carefully remove the retainer springs and brake shoes from = In. / mm. the backing plate.

  • Page 137: Brake Lever Adjustments

    BRAKES Reinstall rear brake components. Use illustration below as 10. Install the swing arm following the procedure outlined in a reference. Chapter 5. Tighten the rear wheel hub nut(s) to specification. Rear Wheel Hub Nut Torque: 58 ft. lbs. (79 Nm) Brake Lever Adjustments Brake Perform the “Brake Lever Adjustment”...
  • Page 138 BRAKES NOTES 6.10...
  • Page 139 CVT SYSTEM CHAPTER 7 CVT SYSTEM CVT SYSTEM ............7.2 CVT MAINTENANCE / INSPECTION.

  • Page 140: Cvt System

    Driven Clutch Operation movement), clutch upshift and backshift. During the development of a Polaris ATV, the CVT system is matched first CVT driven clutches primarily sense torque, but also react to to the engine power curve; then to average riding conditions and RPM, applying and retracting the friction shoes according to the the vehicle’s intended usage.

  • Page 141: Cvt System Drying

    CVT SYSTEM CVT System Drying Allow engine RPM to settle to idle speed, shift transmission to lowest available range and test for belt slippage. Repeat NOTE: If operating the ATV through water, be sure as needed. to check the CVT cover and other ATV components FRONT CVT Drain Plug for water ingestion.

  • Page 142: Clutch Cover Removal

    CVT SYSTEM Clutch Cover Removal Drive Belt Removal Remove the left foot rest. Remove O-ring and nut from driven clutch. Loosen the duct clamps and slide ducts upward off cover. Pull outer sheave of driven toward you and push belt as far as possible into driven sheaves to create belt slack.
  • Page 143 CVT SYSTEM Slide sheave and cam plate off crankshaft as an assembly. Inspect sheave faces (E) for grooves or wear. Check bushings (F) and seals in the moveable sheave. The sleeve NOTE: When removing primary sliding sheave and should be a close, smooth fit in the bushings and seals cam plate assembly, hold cam plate and sliding should fit tightly on the sleeve.

  • Page 144: Drive Clutch Assembly

    CVT SYSTEM Drive Clutch Assembly Apply a very light film of grease to the seal lips and drive clutch sleeve. Then install the sleeve. Open the sheaves of the secondary clutch and push the belt down between the sheaves. Install the driven clutch on the transmission input shaft, looping the belt onto the drive clutch sleeve as shown.

  • Page 145: Driven Clutch Service

    CVT SYSTEM DRIVEN CLUTCH SERVICE Remove the outer roller pin cover by turning and pulling up on the cover. Replace the two sealing O-rings. Driven Clutch Disassembly and Inspection Remove driven clutch assembly by removing O-ring and nut. Remove rollers and pins using a needle-nose pliers and inspect all components.
  • Page 146 CVT SYSTEM To replace friction shoes, remove E-clips that retain the Use a vernier caliper to check the length of the compression backing plate. Use a suitable tool to remove and install the spring. At full extension, the measurement should be no return springs connecting the shoes, using care not to less than 2.74”...

  • Page 147: Driven Clutch Assembly

    CVT SYSTEM Driven Clutch Assembly Install driven clutch hub, then the retaining nut and O-ring. Torque retaining nut to specification. Insert new seals into the outer sheave assembly. Fill the outer sheave cavity with fresh grease and slide onto the inner sheave shaft.
  • Page 148 CVT SYSTEM NOTES 7.10...
  • Page 149 ELECTRICAL CHAPTER 8 ELECTRICAL GENERAL INFORMATION ..........8.2 SPECIAL TOOLS .

  • Page 150: General Information

    ELECTRICAL GENERAL INFORMATION SWITCHES AND CONTROLS Brake Lever Switches Special tools Each brake lever utilizes an electrical brake switch that sends PART NUMBER TOOL DESCRIPTION voltage to activate the starter relay and brake light. Fluke™77 Digital PV-43568 Locate the brake switches on each of the brake levers. Multimeter Disconnect wire harness from brake switch and connect an 2870836...

  • Page 151: Tether Switch Test

    ELECTRICAL Tether Switch Test ETC Operation Disconnect wires from switch. When the throttle is closed (idle) the throttle arm depresses a small micro switch that limits engine rpm. Connect an ohmmeter across the two switch wires (DG and BK/YE). With the boot installed, reading should indicate Throttle Arm continuity.

  • Page 152: Etc Switch Adjustment

    ELECTRICAL ETC Switch Adjustment Key Switch Slide the boot off the throttle cable adjuster and jam nut. The key switch can be tested with an ohm meter. When the key switch is turned to the “ON” position, there should Set parking brake. be continuity between the red (RD) and brown (BN) wires.

  • Page 153: Daytime Running Lights

    ELECTRICAL DAYTIME RUNNING LIGHTS “DRL” Lamp Replacement If the daytime running lights do not operate, lamp replacement “DRL” Test may be required. Install only the recommended replacement lamps. The daytime running lights are powered by an AC current from the Generator / Stator. Predator 50 / Outlaw 90: If running lights are not working, perform the following: Locate the lamp socket (1)(2) below the front cover.

  • Page 154: Tail Light

    ELECTRICAL TAIL LIGHT Remove the nut from the backside of the indicator lamp. Tail Light Lamp Replacement If the tail light lamp does not work, the lamp may need to be replaced. Cover Lamp Screws Sportsman 90 Shown Remove the lamp. Install new lamp(s) into the cover or pod and secure with retaining nut.

  • Page 155: Transmission Switch

    ELECTRICAL TRANSMISSION SWITCH Transmission Switch - Circuit Breakout Testing Removal With the switch installed, use an ohmmeter to test Remove the CVT cover. The indicator switch will be continuity between the switch leads and engine ground. visible between the drive and driven clutch. Refer to CVT Chapter for CVT cover removal and installation.

  • Page 156: Installation

    ELECTRICAL IGNITION SYSTEM Inspect the shift indicator contacts, shift drum, pin and spring. Verify the pin is not sticking in the drum or is damaged. Replace any worn or damaged components. Overview INSPECT The Youth ATV ignition system consists of a simple magneto- driven system that includes a stator Pulser Coil, CDI Box, Ignition Coil and related wiring / connectors.

  • Page 157: Ignition System Testing

    ELECTRICAL Ignition System Testing Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and tight. Use the following flow chart as a guide for troubleshooting. NOTE: The brown (BN) wire on youth models carries 12V key-on power. Condition: No spark or intermittent spark.

  • Page 158: Rpm Ignition Limiter Functions

    ELECTRICAL RPM Ignition Limiter Functions NOTE: The CDI box reads the RPM signal from the stator. The CDI box acts as a limiter by retarding the ignition timing if RPM reaches the specified limit. In reverse gear, the CDI box retards ignition timing and limits RPM once it receives a ground path from the transmission switch dark blue (DB) wire indicating the ATV is in reverse.

  • Page 159: Rpm Limiter Specifications

    ELECTRICAL RPM Limiter Specifications Pulser Coil Output / Resistance Tests Disconnect the 4-wire connector at the CDI box. Install the Peak Ignition Model Max RPM Reading Adaptor (PV-39991) to your meter and connect one Timing meter lead to the dark blue / black wire (DB/BK) and the other 50cc 7400 33.5°...

  • Page 160: Charging System

    ELECTRICAL CHARGING SYSTEM Charging System Testing Whenever charging system problems are suspected, proceed with the following system checks: Remove the battery and properly Using a volt meter, set it to read D.C. volts, service. Reinstall the fully charged measure the battery open circuit voltage battery or a fully charged shop battery.

  • Page 161: Main Fuse / Fuse Holder Location

    ELECTRICAL Main Fuse / Fuse Holder Location Stator / Alternator Tests A 7 Amp fuse protects the main electrical system on all youth Two tests can be performed using a multimeter to determine the models. See illustrations for fuse locations. condition of the stator (alternator).

  • Page 162: Battery

    ELECTRICAL BATTERY New Battery Activation Battery Maintenance Service Notes WARNING WARNING Battery electrolyte is poisonous. It contains sul- furic acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from External: Flush with water.

  • Page 163: Battery Removal

    ELECTRICAL Battery Removal - 50cc Remove the battery from the ATV. CAUTION WARNING To reduce the chance of sparks: Improperly connecting or disconnecting battery Whenever removing the battery, disconnect the cables can result in an explosion and cause negative (black) cable first. When reinstalling the serious injury or death.

  • Page 164: Battery Cleaning / Installation

    For this reason, a battery capacity or load test should be capabilities. Polaris recommends using the Christie Multi conducted whenever poor battery performance is suspected. To Battery Charger (PV-67030), available from tool provider SPX perform this test: for charging batteries.

  • Page 165: Battery Storage

    ELECTRICAL Battery Storage Starter Motor Service Whenever the vehicle is not used for a period of three months or The starter motor is a complete service part. If it is determined more, remove the battery from the vehicle, ensure that it's fully that the starter motor is the failed part, replace as needed.

  • Page 166: Starter Brush Inspection / Replacement

    ELECTRICAL Remove the three screws and washers. Remove the brush plate and brushes. Measure the brush length and replace if worn past the service limit. 0.20” (5 mm) Remove magnet housing while holding the armature and brush holder section together. Brush Length Service Limit 0.20“...

  • Page 167: Starter Reassembly

    ELECTRICAL Voltage Drop Test Measure the resistance between each commutator segment and the armature shaft. The reading should be infinite. (no The Voltage Drop Test is used to test for bad connections. When continuity) performing the test, you are testing the amount of voltage drop through the connection.

  • Page 168: Starter System Testing

    ELECTRICAL Starter System Testing Condition: Starter motor fails to turn engine. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. 8.20...
  • Page 169 WIRE DIAGRAM 2009 PREDATOR 50 WD.1...
  • Page 170 WIRE DIAGRAM 2009 OUTLAW 90 / SPORTSMAN 90 WD.2...

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