2009 Polaris Youth 4stroke Master Service Repair Manual
TABLE OF CONTENTS:
GENERAL INFORMATION
MAINTENANCE
ENGINE/TRANSMISSION
FUEL SYSTEM
BODY/SUSPENSION/STEERING
BRAKES
CVT SYSTEM
ELECTRICAL
GENERAL INFORMATION 1
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 SPECIFICATIONS1 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 NUMBERS1 6
PAINT CODES 1 6
REPLACEMENT KEYS 1 6
SPECIAL TOOLS – WHERE USED 1 7
STANDARD TORQUE SPECIFICATIONS1 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
MAINTENANCE
2 PERIODIC MAINTENANCE CHART 2 3
PERIODIC MAINTENANCE OVERVIEW 2 3
MAINTENANCE CHART KEY 2 3
PRE-RIDE – 40 HOUR MAINTENANCE INTERVAL 2 4
50 – 300 HOUR MAINTENANCE INTERVAL 2 5
POLARIS LUBRICANTS AND SERVICE PRODUCTS 2 6
MAINTENANCE REFERENCES2 7
GENERAL VEHICLE INSPECTION AND MAINTENANCE2 8
PRE-RIDE / DAILY INSPECTION 2 8
VEHICLE COMPONENT INSPECTION LOCATIONS 2 8
FRAME, NUTS, BOLTS AND FASTENER INSPECTION 2 9
STANDARD TORQUE SPECIFICATIONS2 9
KICK-START LEVER AND OPERATION 2 9
FUEL SYSTEM AND AIR INTAKE 2 10
FUEL SYSTEM SAFETY 2 10
SPEED CONTROL SYSTEM 2 10
THROTTLE STOP SPEED CONTROL SYSTEM2 10
ELECTRONIC THROTTLE CONTROL (ETC) 2 10
ETC OPERATION2 11
ETC SWITCH ADJUSTMENT 2 11
CHOKE CABLE ADJUSTMENT 2 12
IDLE SPEED ADJUSTMENT 2 12
FUEL LINES 2 12
PILOT AIR SCREW ADJUSTMENT2 13
VENT LINES2 13
FUEL FILTER 2 13
FUEL VALVE LOCATION2 14
CARBURETOR DRAINING 2 14
AIR FILTER SERVICE 2 15
AIR BOX SEDIMENT TUBE 2 15
ENGINE 2 16
ENGINE OIL LEVEL 2 16
ENGINE OIL AND FILTER CHANGE 2 16
COMPRESSION / LEAKDOWN TEST 2 17
VALVE CLEARANCE ADJUSTMENT 2 17
ENGINE MOUNTS 2 18
ENGINE FASTENER TORQUE 2 18
CVT DRYING (90CC MODELS) 2 18
EXHAUST SPARK ARRESTOR CLEANING 2 18
TRANSMISSION AND FINAL DRIVE 2 19
TRANSMISSION LUBRICATION 2 19
TRANSMISSION LUBRICANT LEVEL2 19
TRANSMISSION LUBRICANT CHANGE2 19
DRIVE CHAIN INSPECTION – 90CC MODELS 2 20
DRIVE CHAIN INSPECTION – 50CC MODELS 2 20
DRIVE CHAIN ADJUSTMENT – 50 AND 90CC MODELS 2 20
SPROCKET INSPECTION 2 21
2 2
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM 2 21
BATTERY MAINTENANCE SERVICE NOTES 2 21
BATTERY REMOVAL – 50CC 2 22
BATTERY REMOVAL – 90CC 2 22
BATTERY CLEANING 2 22
BATTERY INSTALLATION 2 23
BATTERY STORAGE 2 23
FUSES / FUSE HOLDER LOCATION 2 23
SPARK PLUG INSPECTION 2 23
IGNITION TIMING 2 24
ENGINE / FRAME GROUND 2 24
STEERING AND SUSPENSION 2 24
STEERING 2 24
TIE ROD END / STEERING INSPECTION 2 25
WHEEL ALIGNMENT 2 25
TOE ADJUSTMENT 2 26
FRONT SUSPENSION INSPECTION 2 26
REAR SUSPENSION INSPECTION 2 26
SUSPENSION SPRING ADJUSTMENT 2 27
BRAKE SYSTEM 2 27
BRAKE SYSTEM INSPECTION 2 27
BRAKE LEVER TRAVEL 2 27
BRAKE FREEPLAY 2 28
FRONT BRAKE ADJUSTMENT 2 28
REAR BRAKE ADJUSTMENT 2 29
BRAKE SHOE INSPECTION 2 29
WHEELS AND TIRES 2 29
WHEELS 2 29
WHEEL, HUB AND SPINDLE TORQUE TABLE 2 29
WHEEL INSPECTION 2 29
WHEEL REMOVAL – FRONT / REAR 2 30
WHEEL INSTALLATION – FRONT / REAR 2 30
TIRE PRESSURE2 30
TIRE INSPECTION 2 30
ENGINE / TRANSMISSION
3
ENGINE / TRANSMISSION
ENGINE SERVICE 3 3
ENGINE EXPLODED VIEWS & TORQUE VALUES 3 3
ENGINE EXPLODED VIEWS & TORQUE VALUES 3 4
ENGINE EXPLODED VIEWS & TORQUE VALUES 3 5
SPECIAL TOOLS 3 5
ENGINE SERVICE DATA 3 6
ENGINE SERVICE DATA 3 7
ENGINE SERVICE DATA 3 8
ENGINE SERVICE DATA 3 9
OIL FLOW DIAGRAM 3 10
PISTON / RING IDENTIFICATION 3 11
ACCESSIBLE COMPONENTS3 11
ENGINE REMOVAL 3 11
ENGINE INSTALLATION NOTES 3 12
ENGINE LUBRICATION 3 13
TRANSMISSION LUBRICATION 3 13
ENGINE BREATHER / OIL SEPARATOR 3 13
FINDING TOP DEAD CENTER (TDC) 3 13
TOP-END DISASSEMBLY 3 14
ENGINE DISASSEMBLY3 14
CAM CHAIN TENSIONER REMOVAL 3 14
CAM CHAIN TENSIONER INSPECTION3 14
CYLINDER HEAD REMOVAL 3 15
ROCKER ARM DISASSEMBLY / INSPECTION 3 15
CAMSHAFT REMOVAL 3 16
CAMSHAFT INSPECTION 3 16
CYLINDER HEAD INSPECTION 3 17
CYLINDER HEAD SURFACE INSPECTION 3 17
COMBUSTION CHAMBER INSPECTION 3 17
CYLINDER HEAD DISASSEMBLY 3 17
VALVE INSPECTION 3 18
VALVE SEAT RECONDITIONING 3 19
CYLINDER HEAD ASSEMBLY 3 21
VALVE SEALING TEST 3 22
CYLINDER REMOVAL3 22
CAM CHAIN TENSIONER BLADE 3 22
PISTON REMOVAL 3 22
CYLINDER INSPECTION3 23
CYLINDER HONING PROCEDURE 3 23
HONING TO DEGLAZE 3 23
PISTON INSPECTION 3 24
PISTON RING INSTALLED GAP 3 25
BOTTOM-END DISASSEMBLY 3 25
FLYWHEEL REMOVAL / INSPECTION 3 25
STATOR REMOVAL3 25
OIL PUMP REMOVAL 3 26
CRANKCASE DISASSEMBLY 3 27
CRANKSHAFT REMOVAL 3 27
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION3 27
CRANKCASE OIL STRAINER INSPECTION 3 28
3 2
ENGINE / TRANSMISSION
ENGINE ASSEMBLY3 28
CRANKCASE ASSEMBLY 3 28
PISTON RING INSTALLATION 3 28
PISTON INSTALLATION 3 29
TENSIONER BLADE INSTALLATION 3 29
CYLINDER INSTALLATION3 29
CYLINDER HEAD & CAMSHAFT INSTALLATION 3 30
CAM CHAIN TENSIONER INSTALLATION3 31
TRANSMISSION 3 32
TRANSMISSION DISASSEMBLY AND INSPECTION 3 32
TRANSMISSION INSPECTION 3 35
TRANSMISSION ASSEMBLY 3 37
STARTER DRIVE MECHANISM (ELECTRIC)3 39
KICK START 3 41
KICK START DISASSEMBLY / INSPECTION 3 41
KICK START ASSEMBLY 3 42
TROUBLESHOOTING 3 44
SPARK PLUG FOULING 3 44
ENGINE (GENERAL) 3 44
FUEL SYSTEM
4
CARBURETION SYSTEM 4 2
SPECIAL TOOLS 4 2
CARBURETOR FUNCTION 4 2
CARBURETION SPECIFICATIONS 4 3
CARBURETOR OPERATION 4 3
OPERATION OVERVIEW 4 3
FLOAT SYSTEM4 4
PILOT JET 4 4
PILOT MIXTURE SCREW 4 4
AIR / FUEL MIXTURE RATIO4 5
JET NEEDLE 4 5
NEEDLE JET 4 5
THROTTLE OPENING VS FUEL FLOW 4 6
THROTTLE SLIDE 4 6
MAIN JET 4 6
PILOT SYSTEM (IDLE – 3/8 THROTTLE) 4 7
SLIDE CUTAWAY (1/8 – 3/8 THROTTLE) 4 7
JET NEEDLE / NEEDLE JET (3/8 – 3/4 THROTTLE)4 8
MAIN SYSTEM (3/4 TO FULL THROTTLE) 4 8
FUEL DELIVERY 4 9
VENT SYSTEM 4 9
CARBURETOR SERVICE 4 9
CARBURETOR FLOAT BOWL DRAINING 4 9
CARBURETOR REMOVAL – GENERAL 4 10
CARBURETOR DISASSEMBLY – 50CC (MIKUNI) 4 10
CARBURETOR DISASSEMBLY – 90CC (KEIHIN) 4 11
CARBURETOR CLEANING 4 12
CARBURETOR INSPECTION 4 13
FLOAT HEIGHT ADJUSTMENT 4 14
CARBURETOR ASSEMBLY 4 14
NEEDLE AND SEAT LEAK TEST 4 14
FUEL TANK EXPLODED VIEW 4 15
FUEL TANK REMOVAL 4 16
FUEL VALVE LOCATION4 16
FUEL VALVE SERVICE PREDATOR 50 / OUTLAW 90 4 17
FUEL VALVE LAYOUT 4 17
AIR CLEANER EXPLODED VIEW 4 18
TROUBLESHOOTING 4 19
FUEL STARVATION / LEAN MIXTURE 4 19
RICH MIXTURE 4 19
POOR IDLE 4 19
BODY / SUSPENSION / STEERING
5
GENERAL INFORMATION 5 2
SPECIAL TOOLS 5 2
TORQUE SPECIFICATIONS 5 2
BODY REMOVAL – PREDATOR 50 5 2
BODY REMOVAL 5 2
FOOTWELL REMOVAL 5 3
FRONT BUMPER REMOVAL / INSTALLATION 5 4
PREDATOR 50 – BODY EXPLODED VIEW 5 4
BODY REMOVAL – OUTLAW 905 5
REAR CAB REMOVAL 5 5
SIDE PANEL REMOVAL 5 5
FOOTWELL REMOVAL 5 5
FRONT CAB REMOVAL5 6
FRONT BUMPER REMOVAL / INSTALLATION 5 6
OUTLAW 90 – BODY EXPLODED VIEW 5 7
BODY REMOVAL – SPORTSMAN 90 5 8
REAR CAB REMOVAL 5 8
SIDE PANEL REMOVAL 5 8
FOOTWELL REMOVAL 5 8
FRONT CAB REMOVAL5 9
BUMPER AND RACK REMOVAL 5 10
SPORTSMAN 90 – BODY EXPLODED VIEW 5 10
INDICATOR LIGHT / IGNITION SWITCH REPLACEMENT 5 11
SUSPENSION 5 11
50CC SHOCKS AND SPRINGS 5 11
90CC SHOCKS AND SPRINGS 5 11
FRONT SHOCK REMOVAL 5 12
REAR SHOCK REMOVAL 5 12
FRONT CONTROL ARM – 50CC 5 12
CONTROL ARM EXPLODED VIEW5 12
CONTROL ARM REPLACEMENT 5 13
FRONT A-ARM – 90CC 5 14
A-ARM EXPLODED VIEW 5 14
A-ARM REPLACEMENT 5 14
SWING ARM 5 15
REMOVAL 5 15
STEERING – 50CC 5 17
STEERING ASSEMBLY EXPLODED VIEW 5 17
STEERING POST REMOVAL 5 17
STEERING – 90CC 5 18
STEERING ASSEMBLY EXPLODED VIEW 5 18
STEERING POST REMOVAL 5 18
TIE ROD 5 19
REMOVAL / ADJUSTMENT 5 19
HANDLEBAR5 20
PREDATOR 50 EXPLODED VIEW 5 20
OUTLAW 90 EXPLODED VIEW 5 20
SPORTSMAN 90 EXPLODED VIEW 5 20
DECAL REPLACEMENT 5 20
CHAPTER 6
BRAKES
6
SPECIFICATIONS 6 2
GENERAL SPECIFICATIONS 6 2
TORQUE SPECIFICATIONS 6 2
FRONT BRAKES6 3
EXPLODED VIEW 6 3
FRONT BRAKE SERVICE 6 3
REAR BRAKE 6 7
EXPLODED VIEW 6 7
REAR BRAKE SERVICE 6 7
BRAKE LEVER ADJUSTMENTS 6 9
CVT SYSTEM 7
CVT SYSTEM 7 2
CVT MAINTENANCE / INSPECTION7 2
DRIVE CLUTCH OPERATION 7 2
DRIVEN CLUTCH OPERATION7 2
CVT SYSTEM DRYING 7 3
CVT OVERHEATING / DIAGNOSIS 7 3
CLUTCH COVER REMOVAL7 4
DRIVE BELT REMOVAL 7 4
DRIVE CLUTCH SERVICE 7 4
DRIVE CLUTCH DISASSEMBLY AND INSPECTION 7 4
DRIVE CLUTCH ASSEMBLY7 6
DRIVEN CLUTCH SERVICE 7 7
DRIVEN CLUTCH DISASSEMBLY AND INSPECTION7 7
DRIVEN CLUTCH ASSEMBLY 7 9
ELECTRICAL
8
GENERAL INFORMATION 8 2
SPECIAL TOOLS 8 2
ELECTRICAL SYSTEM SERVICE NOTES 8 2
SWITCHES AND CONTROLS 8 2
BRAKE LEVER SWITCHES 8 2
TETHER SWITCH TEST 8 3
ELECTRONIC THROTTLE CONTROL (ETC) 8 3
ETC SWITCH ADJUSTMENT 8 4
KEY SWITCH 8 4
LEFT HAND SWITCH ASSEMBLY 8 4
DAYTIME RUNNING LIGHTS 8 5
“DRL” TEST / LAMP REPLACEMENT 8 5
TAIL LIGHT 8 6
TAIL LIGHT LAMP REPLACEMENT 8 6
INDICATOR LAMPS (90CC MODELS) 8 6
INDICATOR LAMP REPLACEMENT 8 6
TRANSMISSION SWITCH 8 7
TRANSMISSION SWITCH – CIRCUIT BREAKOUT 8 7
TESTING / REMOVAL 8 7
INSTALLATION 8 8
IGNITION SYSTEM8 8
OVERVIEW / TROUBLESHOOTING 8 8
IGNITION SYSTEM TESTING 8 9
RPM IGNITION LIMITER FUNCTIONS 8 10
RPM LIMITER SPECIFICATIONS 8 11
IGNITION COIL TEST 8 11
CDI OUTPUT TEST USING PEAK READING ADAPTOR 8 11
PULSER COIL OUTPUT / RESISTANCE TESTS 8 11
CHARGING SYSTEM 8 12
CHARGING SYSTEM TESTING 8 12
MAIN FUSE / FUSE HOLDER LOCATION 8 13
VOLTAGE REGULATOR / RECTIFIER 8 13
STATOR / ALTERNATOR TESTS 8 13
BATTERY 8 14
BATTERY MAINTENANCE SERVICE NOTES 8 14
NEW BATTERY ACTIVATION 8 14
BATTERY REMOVAL 8 15
BATTERY CLEANING / INSTALLATION 8 16
BATTERY VOLTAGE TEST / LOAD TEST 8 16
BATTERY CHARGING PROCEDURE8 16
BATTERY STORAGE 8 17
STARTER SYSTEM 8 17
STARTER RELAY 8 17
STARTER MOTOR SERVICE / DISASSEMBLY 8 17
STARTER BRUSH INSPECTION / REPLACEMENT 8 18
ARMATURE TEST 8 18
STARTER REASSEMBLY 8 19
VOLTAGE DROP TEST 8 19
STARTER SYSTEM TROUBLESHOOTING 8 19
STARTER SYSTEM TESTING 8 20
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