Polaris Predator 50, Outlaw 90 & Sportsman 90 ATV Repair Service Manual 2009

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This workshop repair service manual PDF download for the 2009 Polaris Predator 50, Outlaw 90 & Sportsman 90 has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

MODEL : 2009 PREDATOR 50
MODEL NUMBER : A09KA05AB, AD
ENGINE MODEL : M10A

MODEL : 2009 OUTLAW 90
MODEL NUMBER : A09KA09AB, AD
ENGINE MODEL : H18S

MODEL : 2009 SPORTSMAN 90
MODEL NUMBER : A09FA09AA, AB
ENGINE MODEL : H18S

TABLE OF CONTENTS :

CH 01-GENERAL INFORMATION
CH 02-MAINTENANCE
CH 03-ENGINE / TRANSMISSION
CH 04-FUEL SYSTEM
CH 05-BODY / SUSPENSION / STEERING
CH 06-BRAKES
CH 07-CVT SYSTEM
CH 08-ELECTRICAL
WIRE DIAGRAM

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 9921800
Total Pages : 170

This manual contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

9921800_CH 01-GENERAL INFORMATION
CH 1 – TABLE OF CONTENTS
MODEL INFORMATION
Model Identification
Engine Designation Numbers
VIN Identification
Engine Serial Number Location
Vehicle Identification Number Location
GENERAL SPECIFICATIONS
MODEL: 2009 PREDATOR 50
MODEL: 2009 OUTLAW 90
MODEL: 2009 SPORTSMAN 90
MODEL: 2009 PREDATOR 50
MODEL: 2009 OUTLAW / SPORTSMAN 90
MISCELLANEOUS INFORMATION
Publication Numbers
Paint Codes
Replacement Keys
Special Tools – Where Used
Standard Torque Specifications
Conversion Table
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Glossary Of Terms
9921800_CH 02-MAINTENANCE
TABLE OF CONTENTS
PERIODIC MAINTENANCE CHART
Periodic Maintenance Overview
Maintenance Chart Key
Pre-Ride – 40 Hour Maintenance Interval
50 – 300 Hour Maintenance Interval
POLARIS LUBRICANTS AND SERVICE PRODUCTS
MAINTENANCE REFERENCES
GENERAL VEHICLE INSPECTION AND MAINTENANCE
Pre-Ride / Daily Inspection
Vehicle Component Inspection Locations
Frame, Nuts, Bolts and Fastener Inspection
Standard Torque Specifications
Kick-Start Lever and Operation
FUEL SYSTEM AND AIR INTAKE
Fuel System Safety
Speed Control System
Throttle Stop Speed Control System
Electronic Throttle Control (ETC)
ETC Operation
ETC Switch Adjustment
Choke Cable Adjustment
Idle Speed Adjustment
Fuel Lines
Pilot Air Screw Adjustment
Vent Lines
Fuel Filter
Fuel Valve Location
Carburetor Draining
Air Filter Service
Air Box Sediment Tube
ENGINE
Engine Oil Level
Engine Oil and Filter Change
Compression / Leakdown Test
Valve Clearance Adjustment
Engine Mounts
Engine Fastener Torque
CVT Drying (90cc Models)
Exhaust Spark Arrestor Cleaning
TRANSMISSION AND FINAL DRIVE
Transmission Lubrication
Transmission Lubricant Level
Transmission Lubricant Change
Drive Chain Inspection – 90cc Models
Drive Chain Inspection – 50cc Models
Drive Chain Adjustment – 50 and 90cc Models
Sprocket Inspection
ELECTRICAL AND IGNITION SYSTEM
Battery Maintenance Service Notes
Battery Removal – 50cc
Battery Removal – 90cc
Battery Cleaning
Battery Installation
Battery Storage
Fuses / Fuse Holder Location
Spark Plug Inspection
Ignition Timing
Engine / Frame Ground
STEERING and SUSPENSION
Steering
Tie Rod End / Steering Inspection
Wheel Alignment
Toe Adjustment
Front Suspension Inspection
Rear Suspension Inspection
Suspension Spring Adjustment
BRAKE SYSTEM
Brake System Inspection
Brake Lever Travel
Brake Freeplay
Front Brake Adjustment
Rear Brake Adjustment
Brake Shoe Inspection
WHEELS AND TIRES
Wheels
Wheel, Hub and Spindle Torque Table
Wheel Inspection
Wheel Removal – Front / Rear
Wheel Installation – Front / Rear
Tire Pressure
Tire Inspection
9921800_CH 03-ENGINE / TRANSMISSION
TABLE OF CONTENTS
ENGINE SERVICE
Engine Exploded Views & Torque Values
Engine Exploded Views & Torque Values
Engine Exploded Views & Torque Values
Special Tools
Engine Service Data
Engine Service Data
Engine Service Data
Engine Service Data
Oil Flow Diagram
Piston / Ring Identification
Accessible Components
Engine Removal
Engine Installation Notes
Engine Lubrication
Transmission Lubrication
Engine Breather / Oil Separator
Finding Top Dead Center (TDC)
TOP-END DISASSEMBLY
Engine Disassembly
Cam Chain Tensioner Removal
Cam Chain Tensioner Inspection
Cylinder Head Removal
Rocker Arm Disassembly / Inspection
Camshaft Removal
Camshaft Inspection
Cylinder Head Inspection
Cylinder Head Surface Inspection
Combustion Chamber Inspection
Cylinder Head Disassembly
Valve Inspection
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Cylinder Removal
Cam Chain Tensioner Blade
Piston Removal
Cylinder Inspection
Cylinder Honing Procedure
Honing To Deglaze
Piston Inspection
Piston Ring Installed Gap
BOTTOM-END DISASSEMBLY
Flywheel Removal / Inspection
Stator Removal
Oil Pump Removal
Crankcase Disassembly
Crankshaft Removal
Crankshaft / Cam Chain / Sprocket Inspection
Crankcase Oil Strainer Inspection
ENGINE ASSEMBLY
Crankcase Assembly
Piston Ring Installation
Piston Installation
Tensioner Blade Installation
Cylinder Installation
Cylinder Head & Camshaft Installation
Cam Chain Tensioner Installation
TRANSMISSION
Transmission Disassembly and Inspection
Transmission Inspection
Transmission Assembly
Starter Drive Mechanism (Electric)
KICK START
Kick Start Disassembly / Inspection
Kick Start Assembly
TROUBLESHOOTING
Spark Plug Fouling
Engine (General)
9921800_CH 04-FUEL SYSTEM
TABLE OF CONTENTS
CARBURETION SYSTEM
Special Tools
Carburetor Function
Carburetion Specifications
CARBURETOR OPERATION
Operation Overview
Float System
Pilot Jet
Pilot Mixture Screw
Air / Fuel Mixture Ratio
Jet Needle
Needle Jet
Throttle Opening vs. Fuel Flow
Throttle slide
Main Jet
Pilot System (Idle – 3/8 Throttle)
Slide Cutaway (1/8 – 3/8 Throttle)
Jet Needle / Needle Jet (3/8 – 3/4 Throttle)
Main System (3/4 to Full Throttle)
Fuel Delivery
Vent System
CARBURETOR SERVICE
Carburetor Float Bowl Draining
Carburetor Removal – General
Carburetor Disassembly – 50cc (Mikuni)
Carburetor Disassembly – 90cc (Keihin)
Carburetor Cleaning
Carburetor Inspection
Float Height Adjustment
Carburetor Assembly
Needle and Seat Leak Test
FUEL TANK EXPLODED VIEW
Fuel Tank Removal
Fuel Valve Location
Fuel Valve Service Predator 50 / Outlaw 90
Fuel Valve Layout
AIR CLEANER EXPLODED VIEW
TROUBLESHOOTING
Fuel Starvation / Lean Mixture
Rich Mixture
Poor Idle
9921800_CH 05-BODY / SUSPENSION / STEERING
TABLE OF CONTENTS
GENERAL INFORMATION
Special Tools
Torque Specifications
BODY REMOVAL – Predator 50
Body Removal
Footwell Removal
Front Bumper Removal / Installation
Predator 50 – Body Exploded View
BODY REMOVAL – Outlaw 90
Rear Cab Removal
Side Panel Removal
Footwell Removal
Front Cab Removal
Front Bumper Removal / Installation
Outlaw 90 – Body Exploded View
BODY REMOVAL – Sportsman 90
Rear Cab Removal
Side Panel Removal
Footwell Removal
Front Cab Removal
Bumper and Rack Removal
Sportsman 90 – Body Exploded View
Indicator Light / Ignition Switch Replacement
SUSPENSION
50cc Shocks and Springs
90cc Shocks and Springs
Front Shock Removal
Rear Shock Removal
FRONT CONTROL ARM – 50cc
Control Arm Exploded View
Control Arm Replacement
FRONT A-ARM – 90cc
A-arm Exploded View
A-arm Replacement
SWING ARM
Removal
STEERING – 50cc
Steering Assembly Exploded View
Steering Post Removal
STEERING – 90cc
Steering Assembly Exploded View
Steering Post Removal
TIE ROD
Removal / Adjustment
HANDLEBAR
Predator 50 Exploded View
Outlaw 90 Exploded View
Sportsman 90 Exploded View
DECAL REPLACEMENT
9921800_CH 06-BRAKES
TABLE OF CONTENTS
SPECIFICATIONS
General Specifications
Torque Specifications
FRONT BRAKES
Exploded View
Front Brake Service
REAR BRAKE
Exploded View
Rear Brake Service
Brake Lever Adjustments
9921800_CH 07-CVT SYSTEM
TABLE OF CONTENTS
CVT SYSTEM
CVT Maintenance / Inspection
Drive Clutch Operation
Driven Clutch Operation
CVT System Drying
CVT Overheating / Diagnosis
Clutch Cover Removal
Drive Belt Removal
DRIVE CLUTCH SERVICE
Drive Clutch Disassembly and Inspection
Drive Clutch Assembly
DRIVEN CLUTCH SERVICE
Driven Clutch Disassembly and Inspection
Driven Clutch Assembly
9921800_CH 08-ELECTRICAL
TABLE OF CONTENTS
GENERAL INFORMATION
Special tools
Electrical System Service Notes
SWITCHES AND CONTROLS
Brake Lever Switches
Tether Switch Test
Electronic Throttle Control (ETC)
ETC Operation
ETC Switch Adjustment
Key Switch
Left Hand Switch Assembly
DAYTIME RUNNING LIGHTS
“DRL” Test
“DRL” Lamp Replacement
TAIL LIGHT
Tail Light Lamp Replacement
INDICATOR LAMPS (90cc Models)
Indicator Lamp Replacement
TRANSMISSION SWITCH
Transmission Switch – Circuit Breakout
Testing
Removal
Installation
IGNITION SYSTEM
Overview
Ignition System Troubleshooting
Ignition System Testing
RPM Ignition Limiter Functions
RPM Limiter Specifications
Ignition Coil Test
CDI Output Test Using Peak Reading Adaptor
Pulser Coil Output / Resistance Tests
CHARGING SYSTEM
Charging System Testing
Main Fuse / Fuse Holder Location
Voltage Regulator / Rectifier
Stator / Alternator Tests
BATTERY
Battery Maintenance Service Notes
New Battery Activation
Battery Removal – 50cc
Battery Removal – 90cc
Battery Cleaning
Battery Installation
Battery Voltage Test
Battery Load Test
Battery Charging Procedure
Battery Storage
STARTER SYSTEM
Starter Relay
Starter Motor Service
Starter Disassembly
Starter Brush Inspection / Replacement
Armature Test
Starter Reassembly
Voltage Drop Test
Starter System Troubleshooting
Starter System Testing
9921800_WIRE DIAGRAM
2009 Predator 50
2009 Outlaw and Sportsman 90

 

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Polaris Predator 50, Outlaw 90 & Sportsman 90 ATV Repair Service Manual 2009.pdf

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