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

-
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.

More Info : http://www.sitelux.com

-

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
    
    -