Polaris 2006 Predator 5090 & Sportsman 90 Service Manual – PDF

Description

Polaris 2006 Predator 5090 & Sportsman 90 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Polaris 2006 Predator 5090 & Sportsman 90 Service Manual – PDF DOWNLOAD

Language : English
Pages : 126
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Polaris 2006 Predator 5090 & Sportsman 90 Service Manual – PDF DOWNLOAD

GENERAL INFORMATION 1
MODEL NUMBER INFORMATION 2
MODEL NUMBER 2
ENGINE DESIGNATION NUMBERS 2
VIN IDENTIFICATION 2
ENGINE AND MACHINE SERIAL NUMBERS 2
HIGH ALTITUDE OPERATION 2
2006 P REDATOR 50 SPECIFICATIONS 3
MODEL NUMBER: A06KA05CA 3
2006 PREDATOR 90 SPECIFICATIONS 5
MODEL NUMBER: A06KA09CA 5
2006 SPORTSMAN 90 SPECIFICATIONS 7
MODEL NUMBER: A06FA09CA 7
MISC NUMBERS/CHARTS 9
PUBLICATIONS 9
PAINT CODES 9
REPLACEMENT KEYS 9
STANDARD TORQUE SPECIFICATIONS 10
CONVERSION TABLE 11
SAE TAP DRILL SIZES 12
METRIC TAP DRILL SIZES 12
DECMIAL EQUIVALENTS 12
GLOSSARY OF TERMS 13
SPECIAL TOOLS 14
Special Tools maybe required while servicing the machine Some of the tools listed are mandatory and other tools maybe substituted with a similar tool, if available Polaris recommends the use of Polaris special tools when servicing any Polaris product 14
MAINTENANCE 17
STANDARD TORQUE SPECIFICATIONS 18
Overview 18
MAINTENANCE PRODUCTS 18
ATV 2 CYCLE ENGINES 18
PERIODIC MAINTENANCE CHART 19
Overview 19
PERIODIC MAINTENANCE CHART CONT’D 20
VEHICLE INSPECTION 21
PRE-RIDE / DAILY INSPECTION 21
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS 22
LUBRICANTS/FLUIDS – Youth ATVs 22
LUBRICATION 24
SPEED CONTROLS 25
Speed Control Mandate 25
Electronic Speed Control System 25
CDI Jumper Removal and Installation 25
Throttle Stop Speed Control System 25
Rear Speed Control Tether – 50cc Model 25
BRAKES 26
Adjustments 26
DRIVE CHAIN ADJUSTMENT 27
Inspection – 90cc Models 27
Inspection – 50cc Models 27
Adjustment – 50 and 90cc Models 27
SUSPENSION 28
Front Shocks and Springs 28
Rear Shocks and Springs 28
TRANSMISSION 28
Lubricant Level 28
Checking the level 29
Changing Lubricant 29
CARBURETOR/THROTTLE 29
Throttle Operation 29
Idle Speed Adjustment 29
Air Screw Adjustment 29
Choke (Enrichment) Adjustment 30
Electronic Throttle Control (ETC) Switch Adjustment 30
Carburetor Draining 31
OIL PUMP 31
Oil Pump Bleeding 31
Oil Pump Adjustment 32
Oil Pump Trouble Shooting 32
FUEL AMD OIL SYSTEM 33
Fuel Lines 33
Vent Lines 33
Fuel Filter 33
Oil Tank 33
ENGINE 34
Air Filter Service 34
Compression Test 34
Spark Plug 34
WHEELS AND TIRES 35
Wheel, Hub and Spindle Torque Table 35
Wheel Inspection 35
Wheel Removal 35
Wheel Installation 35
Tire Pressure 35
Tire Inspection 36
STEERING / ALIGNMENT 36
Inspection 36
Camber and Caster 36
Wheel Alignment – Method 1 / Straight Edge or String 36
Wheel Alignment – Method 2 / Chalk Mark 37
Toe Alignment 37
ENGINE 39
SPECIFICATIONS 40
Engine Fastener Torque Specifications 40
Special Tools 40
ENGINE 40
Engine Removal 40
Engine Installation 42
Engine Break-In 42
Engine Disassembly 42
Component Inspection 48
Honing – Cylinder Hone Selection and Procedure 49
Honing to Oversize 50
Cleaning the Cylinder After Honing 50
Crankshaft Run-out 50
Engine Reassembly 51
Muffler Installation 55
TROUBLESHOOTING 56
Spark Plug Fouling 56
Engine Turns Over But Fails To Start 56
Engine Does not Turn over 56
Engine Runs But Will Not Idle 56
Engine Idles But Will Not Accelerate 56
Engine Has Low Power 56
Piston Failure – Scoring 57
Excessive Smoke And Carbon Build-up 57
Low Compression 57
Backfiring 57
Overheating 57
CVT SYSTEM 59
CVT SYSTEM 60
Drive Clutch Disassembly and Inspection 60
Drive Clutch Assembly 61
Driven Clutch Disassembly and Inspection 62
Driven Assembly 64
TRANSMISSION 67
TRANSMISSION 68
Disassembly and Inspection – 90cc 68
Transmission Reassembly – 90cc 71
Transmission Disassembly and Inspection- 50cc 73
Transmission Re-assembly – 50cc 74
KICK START 74
Kick Start Disassembly and Inspection 74
Kick Start Assembly 75
STARTER DRIVE 77
Starter Drive Disassembly and Inspection 77
Starter Drive Assembly 78
BODY / SUSPENSION / STEERING 81
GENERAL INFORMATION 82
Engine Mounting – 90cc 82
Torque Specifications 82
Special Tools 82
ENGINE MOUNTING 83
50cc and 90cc 83
SUSPENSION 83
Shocks and Springs 83
Suspension A-arms 84
STEERING 85
Steering Assembly 85
FUEL AND OIL TANK 86
Fuel Tank 86
Oil Tank 86
BODY PANELS 86
Predator Body Panel Installation 86
Sportsman Front and Rear Body Panel Installation 87
Sportsman Handlebar Installation 88
Predator Handlebar Installation 89
Brake Lever Adjustments 90
BRAKES 91
BRAKES 92
Front Brakes 92
Rear Brake and Swing-arm 93
Brake Lever Adjustments 96
CARBURETOR 97
CARBURETOR 98
Special Tools 99
Carburetor System Function 99
Carburetor Specifications100
Carburetor Optional Jetting100
High Altitude Operation100
CARBURETOR OPERATION101
Operation Overview101
Float System101
Pilot Jet101
Air Screw102
Air/Fuel Mixture Ratio102
Jet Needle 102
Needle Jet103
Throttle Opening vs Fuel Flow103
Throttle Slide103
Main Jet103
Pilot System Overview (Idle-3/8 Throttle)104
Throttle Slide Cutaway (1/8-3/8 Throttle)104
Jet Needle / Needle Jet (3/8-3/4 Throttle)105
Main Jet (3/4-Full Throttle)105
Fuel Delivery (2 Cycle)106
FUEL SYSTEM MAINTENANCE106
Vent System106
Float Height Adjustment106
Needle and Seat Leak Test107
Carburetor Float Bowl Draining107
ELECTRICAL109
GENERAL INFORMATION110
Electrical Service Notes110
Special Tools110
SPEED CONTROL110
Youth Model ATV Speed Restriction110
Electronic Speed Control System110
Throttle Stop Speed Control System111
BATTERY111
Battery Service Notes111
New Battery Activation111
Battery Inspection / Removal112
Battery Installation112
Battery Testing112
Battery Voltage Test113
Battery Load Test113
Battery Charging Procedure113
Off Season Storage and Maintenance114
CHARGING SYSTEM115
Charging System Test Flow Chart115
Current Draw Test – Key Off116
“Break Even” Test116
Alternator Output Test116
STARTER117
Troubleshooting117
Voltage Drop Test117
Starter System Test Flow chart118
Starter Disassembly119
Starter Brush Inspection/Replacement119
Armature Test120
Starter Reassembly120
ELECTRONIC THROTTLE CONTROL (ETC) SWITCH121
Overview121
IGNITION121
Overview121
Ignition System Troubleshooting121
Ignition Coil Test122
Stator Test122
Tether Switch Test (90 & 50cc)122
REVERSE SPEED LIMITER- 90cc122
Overview122
Reverse Limiter Test122
LAMPS123
Brake/Tail Lamp Replacement123
Daytime Running Lamp (DRL) Replacement123
Indicator Lamp Replacement123
WIRE_DIAGRAMS125

DESCRIPTION:

Polaris 2006 Predator 5090 & Sportsman 90 Service Manual – PDF DOWNLOAD

G.B 05/04/25