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A09KA05AB
Polaris A09KA05AB Manuals
Manuals and User Guides for Polaris A09KA05AB. We have
1
Polaris A09KA05AB manual available for free PDF download: Manual
Polaris A09KA05AB Manual (170 pages)
Brand:
Polaris
| Category:
Offroad Vehicle
| Size: 8.3 MB
Table of Contents
Table of Contents
1
Chapter 1
2
Engine Designation Numbers
2
Engine Serial Number Location
2
Model Identification
2
Model Information
2
Vehicle Identification Number Location
2
Vin Identification
2
General Specifications
3
Model: 2009 Predator 50
4
Model: 2009 Outlaw / Sportsman 90
5
Miscellaneous Information
6
Publication Numbers
6
Paint Codes
6
Replacement Keys
6
Special Tools - Where Used
7
Standard Torque Specifications
8
Conversion Table
9
Sae Tap Drill Sizes
10
Metric Tap Drill Sizes
10
Decimal Equivalents
10
Glossary of Terms
11
Chapter 2 Maintenance 2
13
Maintenance Chart Key
15
Periodic Maintenance Chart
15
Periodic Maintenance Overview
15
Pre-Ride - 40 Hour Maintenance Interval
16
50 - 300 Hour Maintenance Interval
17
Polaris Lubricants and Service Products
18
Maintenance References
19
General Vehicle Inspection and Maintenance
20
Pre-Ride / Daily Inspection
20
Vehicle Component Inspection Locations
20
Frame, Nuts, Bolts and Fastener Inspection
21
Standard Torque Specifications
21
Kick-Start Lever and Operation
21
Fuel System and Air Intake
22
Fuel System Safety
22
Speed Control System
22
Throttle Stop Speed Control System
22
Electronic Throttle Control (Etc)
22
Etc Operation
23
Etc Switch Adjustment
23
Choke Cable Adjustment
24
Idle Speed Adjustment
24
Fuel Lines
24
Pilot Air Screw Adjustment
25
Vent Lines
25
Fuel Filter
25
Fuel Valve Location
26
Carburetor Draining
26
Air Filter Service
27
Air Box Sediment Tube
27
Engine
28
Engine Oil Level
28
Engine Oil and Filter Change
28
Compression / Leakdown Test
29
Valve Clearance Adjustment
29
Engine Mounts
30
Engine Fastener Torque
30
Cvt Drying (90Cc Models)
30
Exhaust Spark Arrestor Cleaning
30
Transmission and Final Drive
31
Transmission Lubrication
31
Transmission Lubricant Level
31
Transmission Lubricant Change
31
Drive Chain Inspection - 90Cc Models
32
Drive Chain Inspection - 50Cc Models
32
Drive Chain Adjustment - 50 and 90Cc Models
32
Sprocket Inspection
33
Electrical and Ignition System
33
Battery Maintenance Service Notes
33
Battery Removal - 50Cc
34
Battery Removal - 90Cc
34
Battery Cleaning
34
Battery Installation
35
Battery Storage
35
Fuses / Fuse Holder Location
35
Spark Plug Inspection
35
Ignition Timing
36
Engine / Frame Ground
36
Steering and Suspension
36
Steering
36
Tie Rod End / Steering Inspection
37
Wheel Alignment
37
Toe Adjustment
38
Front Suspension Inspection
38
Rear Suspension Inspection
38
Suspension Spring Adjustment
39
Brake System
39
Brake System Inspection
39
Brake Lever Travel
39
Brake Freeplay
40
Front Brake Adjustment
40
Rear Brake Adjustment
41
Brake Shoe Inspection
41
Wheels and Tires
41
Wheels
41
Wheel, Hub and Spindle Torque Table
41
Wheel Inspection
41
Wheel Removal - Front / Rear
42
Wheel Installation - Front / Rear
42
Tire Pressure
42
Tire Inspection
42
Chapter 3 Engine / Transmission
43
Engine Service
45
Engine Exploded Views & Torque Values
46
Engine Exploded Views & Torque Values
47
Engine Service Data
48
Special Tools
48
Engine Service Data
50
Oil Flow Diagram
52
Accessible Components
53
Engine Removal
53
Piston / Ring Identification
53
Engine Installation Notes
54
Engine Breather / Oil Separator
55
Engine Lubrication
55
Finding Top Dead Center (Tdc)
55
Transmission Lubrication
55
Top-End Disassembly
56
Engine Disassembly
56
Cam Chain Tensioner Removal
56
Cam Chain Tensioner Inspection
56
Cylinder Head Removal
57
Rocker Arm Disassembly / Inspection
57
Camshaft Removal
58
Camshaft Inspection
58
Cylinder Head Inspection
59
Cylinder Head Surface Inspection
59
Combustion Chamber Inspection
59
Cylinder Head Disassembly
59
Valve Inspection
60
Valve Seat Reconditioning
61
Cylinder Head Assembly
63
Valve Sealing Test
64
Cylinder Removal
64
Cam Chain Tensioner Blade
64
Piston Removal
64
Cylinder Inspection
65
Cylinder Honing Procedure
65
Honing to Deglaze
65
Piston Inspection
66
Piston Ring Installed Gap
67
Bottom-End Disassembly
67
Flywheel Removal / Inspection
67
Stator Removal
67
Oil Pump Removal
68
Crankcase Disassembly
69
Crankshaft Removal
69
Crankshaft / Cam Chain / Sprocket Inspection
69
Crankcase Oil Strainer Inspection
70
Engine Assembly
70
Crankcase Assembly
70
Piston Ring Installation
70
Piston Installation
71
Tensioner Blade Installation
71
Cylinder Installation
71
Cylinder Head & Camshaft Installation
72
Cam Chain Tensioner Installation
73
Transmission
74
Transmission Disassembly and Inspection
74
Transmission Inspection
77
Transmission Assembly
79
Starter Drive Mechanism (Electric)
81
Kick Start
83
Kick Start Disassembly / Inspection
83
Kick Start Assembly
84
Troubleshooting
86
Spark Plug Fouling
86
Engine (General)
86
Chapter 4 Fuel System
89
Carburetion System
90
Carburetor Function
90
Special Tools
90
Carburetion Specifications
91
Carburetor Operation
91
Operation Overview
91
Float System
92
Pilot Jet
92
Pilot Mixture Screw
92
Air / Fuel Mixture Ratio
93
Jet Needle
93
Needle Jet
93
Throttle Opening Vs. Fuel Flow
94
Throttle Slide
94
Main Jet
94
Pilot System (Idle - 3/8 Throttle)
95
Slide Cutaway (1/8 - 3/8 Throttle)
95
Jet Needle / Needle Jet (3/8 - 3/4 Throttle)
96
Main System (3/4 to Full Throttle)
96
Fuel Delivery
97
Vent System
97
Carburetor Service
97
Carburetor Float Bowl Draining
97
Carburetor Removal - General
98
Carburetor Disassembly - 50Cc (Mikuni)
98
Carburetor Disassembly - 90Cc (Keihin)
99
Carburetor Cleaning
100
Carburetor Inspection
101
Float Height Adjustment
102
Carburetor Assembly
102
Needle and Seat Leak Test
102
Fuel Tank Exploded View
103
Fuel Tank Removal
104
Fuel Valve Location
104
Fuel Valve Service Predator 50 / Outlaw 90
105
Fuel Valve Layout
105
Air Cleaner Exploded View
106
Troubleshooting
107
Fuel Starvation / Lean Mixture
107
Rich Mixture
107
Poor Idle
107
Chapter 5 Body / Suspension / Steering
109
Body Removal - Predator 50
110
Body Removal
110
Footwell Removal
111
Front Bumper Removal / Installation
112
Predator 50 - Body Exploded View
112
General Information
110
Special Tools
110
Torque Specifications
110
Body Removal - Outlaw 90
113
Rear Cab Removal
113
Side Panel Removal
113
Footwell Removal
113
Front Cab Removal
114
Front Bumper Removal / Installation
114
Outlaw 90 - Body Exploded View
115
Body Removal - Sportsman 90
116
Rear Cab Removal
116
Side Panel Removal
116
Footwell Removal
116
Front Cab Removal
117
Bumper and Rack Removal
118
Sportsman 90 - Body Exploded View
118
Indicator Light / Ignition Switch Replacement
119
Suspension
119
50Cc Shocks and Springs
119
Front Shock Removal
120
Rear Shock Removal
120
Front Control Arm - 50Cc
120
Control Arm Exploded View
120
Control Arm Replacement
121
Front A-Arm - 90Cc
122
A-Arm Exploded View
122
A-Arm Replacement
122
Swing Arm
123
Removal
123
Steering - 50Cc
125
Steering Assembly Exploded View
125
Steering Post Removal
125
Steering - 90Cc
126
Steering Assembly Exploded View
126
Steering Post Removal
126
Tie Rod
127
Removal / Adjustment
127
Decal Replacement
128
Handlebar
128
Predator 50 Exploded View
128
Outlaw 90 Exploded View
128
Sportsman 90 Exploded View
128
Chapter 6 Brakes
129
General Specifications
130
Specifications
130
Torque Specifications
130
Front Brakes
131
Exploded View
131
Front Brake Service
131
Rear Brake
135
Exploded View
135
Rear Brake Service
135
Brake Lever Adjustments
137
Chapter 7 Cvt System
139
Cvt Maintenance / Inspection
140
Cvt System
140
Drive Clutch Operation
140
Driven Clutch Operation
140
Cvt Overheating / Diagnosis
141
Cvt System Drying
141
Clutch Cover Removal
142
Drive Belt Removal
142
Drive Clutch Service
142
Drive Clutch Disassembly and Inspection
142
Drive Clutch Assembly
144
Driven Clutch Service
145
Driven Clutch Disassembly and Inspection
145
Driven Clutch Assembly
147
Chapter 8 Electrical
149
Electrical System Service Notes
150
General Information
150
Special Tools
150
Switches and Controls
150
Brake Lever Switches
150
Tether Switch Test
151
Electronic Throttle Control (Etc)
151
Etc Switch Adjustment
152
Key Switch
152
Left Hand Switch Assembly
152
Daytime Running Lights
153
Drl" Test / Lamp Replacement
153
Indicator Lamps (90Cc Models)
154
Indicator Lamp Replacement
154
Tail Light
154
Tail Light Lamp Replacement
154
Transmission Switch
155
Transmission Switch - Circuit Breakout
155
Installation
156
Ignition System
156
Ignition System Testing
157
Rpm Ignition Limiter Functions
158
Rpm Limiter Specifications
159
Ignition Coil Test
159
CDI Output Test Using Peak Reading Adaptor
159
Pulser Coil Output / Resistance Tests
159
Charging System
160
Charging System Testing
160
Main Fuse / Fuse Holder Location
161
Voltage Regulator / Rectifier
161
Stator / Alternator Tests
161
Battery
162
Battery Maintenance Service Notes
162
New Battery Activation
162
Battery Removal
163
Battery Cleaning / Installation
164
Battery Voltage Test / Load Test
164
Battery Charging Procedure
164
Battery Storage
165
Starter System
165
Starter Relay
165
Starter Motor Service / Disassembly
165
Starter Brush Inspection / Replacement
166
Armature Test
166
Starter Reassembly
167
Voltage Drop Test
167
Starter System Troubleshooting
167
Starter System Testing
168
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