Polaris 2001 90 SPORTSMAN 90 Manuals

Manuals and User Guides for Polaris 2001 90 SPORTSMAN 90. We have 1 Polaris 2001 90 SPORTSMAN 90 manual available for free PDF download: Manual

Polaris 2001 90 SPORTSMAN 90 Manual

Polaris 2001 90 SPORTSMAN 90 Manual (125 pages)

Brand: Polaris | Category: Offroad Vehicle | Size: 2.22 MB

Table of Contents

Chapter 1 General Information

1
- Table of Contents
  1
- Model Identification
  3
- Serial Number Location
  3
- Specifications
  4
- Paint Codes
  5
- Publication Numbers
  5
- Standard Torque Specifications
  6
  - Decimal Equivalents
    9
  - Conversion Table
    10
- Decimal Equivalent Chart
  11
  - Sae Tap Drill Sizes
    11
- Glossary of Terms
  12
- Inspection Schedule
  14
- Vehicle Inspection
  15
- Transmission Lubrication
  18
- Throttle Operation / Air Screw Adjustment
  19
- Idle Speed Adjustment
  20
- Throttle Cable Adjustment
  20
- Oil Pump Troubleshooting
  23
- Fuel System
  24
  - Fuel Lines
    24
  - Vent Lines
    24
  - Fuel Filter
    24
  - Carburetor Draining
    25
- Air Filter Service
  26
  - Wheel Removal Front or Rear
    27
  - Wheel Installation
    27
  - Tire Pressure
    28
  - Tire Inspection
    28
- Compression Test
  26
- Alignment
  30
Chapter 2 Engine

31
- Special Tools, Engine
  33
- Torque Specifications
  33
- Engine Installation Notes
  34
- Engine Disassembly
  35
- Engine Inspection
  45
  - Honing to Oversize
    48
  - Cleaning the Cylinder after Honing
    48
- Crankshaft Runout Inspection
  49
- Engine Assembly
  50
- Spark Plug Fouling
  59
Chapter 3 Fuel System/Carburetion

63
- Fuel System Warnings
  65
- Carburetor Operation
  66
- Float System
  66
- Pilot Jet / Pilot Air Screw / Air/Fuel Mixture
  67
- Jet Needle / Needle Jet / Throttle Opening
  68
- Pilot System
  70
- Slide Cutaway / 1/8-3/8 Throttle
  71
- Jet Needle/Needle Jet (3/8-3/4 Throttle)
  72
- Main System / 3/4 to Full Throttle
  73
- Fuel Delivery
  74
- Needle and Seat Leakage Test
  75
- Carburetor Float Bowl Draining
  76
- Carburetor Exploded View
  77
- Troubleshooting
  78
Chapter 4 Body and Steering

81
- Frame Photos
  84
- Engine Mounting
  85
- Shocks and Springs
  87
- Suspension A-Arms
  88
- Steering
  89
- Front Brake
  91
- Rear Brake and Axle
  92
- Fuel and Oil Tank
  96
- Front and Rear Cab
  97
- Handlebar
  98
- Muffler
  100
Chapter 5 Electrical

101
- Brakelight Lamp Replacement
  103
- Electrical Service Notes
  103
- Special Tools
  103
- Battery Inspection/Removal
  105
- Battery Installation / Testing
  105
  - Load Test
    106
- Off Season Storage
  107
  - Charging Procedure
    107
- Charging System Testing
  109
- Ignition System
  110
  - Ignition Timing
    110
- CDI Output Test
  112
- Cranking Output Test
  112
- Charging System Testing
  113
- Alternator Output Test (AC Amp)
  115
  - Voltage Drop Test
    116
- Starter System
  117
- Starter Motor Disassembly
  118
- Brush Inspection/Replacement
  119
- Armature Testing
  120
- Starter Assembly
  121
- Electronic Throttle Control (ETC)
  122
- Ignition System Troubleshooting
  123

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