Polaris OUTLAW 90 2009 Youth ATV Manuals

Manuals and User Guides for Polaris OUTLAW 90 2009 Youth ATV. We have 1 Polaris OUTLAW 90 2009 Youth ATV manual available for free PDF download: Manual

Polaris OUTLAW 90 2009 Manual

Polaris OUTLAW 90 2009 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
- 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
- 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
- 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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