Polaris Sportsman 90 - Service Manual - Wiring Diagrams - Owners

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POLARIS SPORTSMAN 90 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS MANUAL

- English Service Manual / Repair Manual, Wiring Diagrams and Owners Manual, for ATV Polaris Sportsman 90.

 
CONTENTS:

SERVICE MANUAL

9921800_CH 01
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
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
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
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
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
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
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
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

OWNERS MANUAL