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Polaris 2009 Predator 50 Outlaw/Sportsman 90 Service Manual – PDF
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Description
Polaris 2009 Predator 50 Outlaw/Sportsman 90 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Polaris 2009 Predator 50 Outlaw/Sportsman 90 Service Manual – PDF DOWNLOAD
Language : English
Pages : 170
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Polaris 2009 Predator 50 Outlaw/Sportsman 90 Service Manual – PDF DOWNLOAD
9921800_CH 01................................................ 1 CH 1 - TABLE OF CONTENTS................................. 1 MODEL INFORMATION.................................... 2 Model Identification............................. 2 Engine Designation Numbers....................... 2 VIN Identification............................... 2 Engine Serial Number Location.................... 2 Vehicle Identification Number Location........... 2 GENERAL SPECIFICATIONS............................... 3 MODEL: 2009 PREDATOR 50.......................... 3 MODEL: 2009 OUTLAW 90............................ 3 MODEL: 2009 SPORTSMAN 90......................... 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 9921800_CH 02................................................ 13 TABLE OF CONTENTS........................................ 13 PERIODIC MAINTENANCE CHART........................... 15 Periodic Maintenance Overview.................... 15 Maintenance Chart Key............................ 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 9921800_CH 03................................................ 43 TABLE OF CONTENTS........................................ 43 ENGINE SERVICE....................................... 45 Engine Exploded Views & Torque Values ........... 45 Engine Exploded Views & Torque Values ........... 46 Engine Exploded Views & Torque Values ........... 47 Special Tools.................................... 48 Engine Service Data.............................. 48 Engine Service Data.............................. 49 Engine Service Data.............................. 50 Engine Service Data.............................. 51 Oil Flow Diagram................................. 52 Piston / Ring Identification..................... 53 Accessible Components............................ 53 Engine Removal................................... 53 Engine Installation Notes........................ 54 Engine Lubrication............................... 55 Transmission Lubrication......................... 55 Engine Breather / Oil Separator.................. 55 Finding Top Dead Center (TDC).................... 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 9921800_CH 04................................................ 89 TABLE OF CONTENTS........................................ 89 CARBURETION SYSTEM................................... 90 Special Tools.................................... 90 Carburetor Function.............................. 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 9921800_CH 05................................................109 TABLE OF CONTENTS........................................109 GENERAL INFORMATION..................................110 Special Tools....................................110 Torque Specifications............................110 BODY REMOVAL - Predator 50...........................110 Body Removal.....................................110 Footwell Removal.................................111 Front Bumper Removal / Installation..............112 Predator 50 - Body Exploded View.................112 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 90cc 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 HANDLEBAR............................................128 Predator 50 Exploded View........................128 Outlaw 90 Exploded View..........................128 Sportsman 90 Exploded View.......................128 DECAL REPLACEMENT....................................128 9921800_CH 06................................................129 TABLE OF CONTENTS........................................129 SPECIFICATIONS.......................................130 General 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 9921800_CH 07................................................139 TABLE OF CONTENTS........................................139 CVT SYSTEM...........................................140 CVT Maintenance / Inspection.....................140 Drive Clutch Operation...........................140 Driven Clutch Operation..........................140 CVT System Drying................................141 CVT Overheating / Diagnosis......................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 9921800_CH 08................................................149 TABLE OF CONTENTS........................................149 GENERAL INFORMATION..................................150 Special tools....................................150 Electrical System Service Notes..................150 SWITCHES AND CONTROLS................................150 Brake Lever Switches.............................150 Tether Switch Test...............................151 Electronic Throttle Control (ETC)................151 ETC Operation....................................151 ETC Switch Adjustment............................152 Key Switch.......................................152 Left Hand Switch Assembly........................152 DAYTIME RUNNING LIGHTS...............................153 “DRL” Test.......................................153 “DRL” Lamp Replacement...........................153 TAIL LIGHT...........................................154 Tail Light Lamp Replacement......................154 INDICATOR LAMPS (90cc Models)........................154 Indicator Lamp Replacement.......................154 TRANSMISSION SWITCH..................................155 Transmission Switch - Circuit Breakout...........155 Testing..........................................155 Removal..........................................155 Installation.....................................156 IGNITION SYSTEM......................................156 Overview.........................................156 Ignition System Troubleshooting..................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 - 50cc...........................163 Battery Removal - 90cc...........................163 Battery Cleaning.................................164 Battery Installation.............................164 Battery Voltage Test.............................164 Battery Load Test................................164 Battery Charging Procedure.......................164 Battery Storage..................................165 STARTER SYSTEM.......................................165 Starter Relay....................................165 Starter Motor Service............................165 Starter 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 9921800_Wire Diagram.........................................169 2009 Predator 50.........................................169 2009 Outlaw and Sportsman 90.............................170
G.B 07/04/25
