2006 POLARIS Predator 50, Outlaw 90, Sportsman 90 YOUTH 4 Stroke Service Repair Shop Manual

1.1 GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION 1 MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 ENGINE AND MACHINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 HIGH ALTITUDE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 2006 PREDATOR 50 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL NUMBER: A06KA05CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 2006 PREDATOR 90 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MODEL NUMBER: A06KA09CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 2006 SPORTSMAN 90 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MODEL NUMBER: A06FA09CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 DECMIAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14 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.

1.2 GENERAL INFORMATION MODEL NUMBER INFORMATION MODEL NUMBER The machine model number must be used with any correspondence regarding warranty or service. ENGINE DESIGNATION NUMBERS AR03-01 - Single, Air Cooled, 2 Stroke, Electric Start AR07-01 - Single, Air Cooled, 2 Stroke, Electric Start VIN IDENTIFICATION ENGINE AND MACHINE SERIAL NUMBERS Record and be sure to refer to the engine model number and serial number whenever corresponding about an engine. This information can be found stamped on the transmission section (A). The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the front of the frame (B). HIGH ALTITUDE OPERATION Polaris Youth ATVs have been tested to 12,000 ft above sea level to assure satisfactory performance. No jetting or clutching changes are required for high altitude operation. NOTE: If desired, removing one CVT roller weight from each tower of the drive clutch and fine-tuning the carburetor with optional jetting may provide a slight improvement in high altitude performance, but generally is not needed. } Machine Model Number Designation } } } A 06 KA 05 CA Year Designation Basic Chassis Designation Engine Designation Emissions & Model Option } 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 World Mfg. ID Engine R F 3 E A 0 5 C * 6 T 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Emissions } Check Digit Model Year Body Style Plant Code Individual Serial Number * - Descriptor could be either a number or a letter Powertrain

1.3 GENERAL INFORMATION 2006 PREDATOR 50 SPECIFICATIONS MODEL NUMBER: A06KA05CA ENGINE MODEL: AR03-01 Table 1-1: A06KA05CA Catagory Dimension / Capacity Length 48 in. / 122 cm Width 31.5 in. / 80 cm Height 28 in. / 71 cm Wheel Base 33 in. / 84 cm Dry Weight 185 lbs. / 84 kg Gross Vehicle Weight 275 lbs. / 124.7 kg Rider Capacity 90 lbs. / 40.8 kg

1.4 GENERAL INFORMATION Table 1-2: A06KA05CA Specifications Engine Platform 2–Stroke Horizontal Engine Model Number AR03-01 Engine Displacement 49.3 cc Number of Cylinders 1 Bore & Stroke (mm) 1.58x1.54″ / 40x39.2 mm Compression Ratio 7.2:1 Compression Pressure 110 PSI / 7.8 kgf/cm2 Engine Idle Speed 1200 RPM ± 200 Engine Max Operating Rpm 4 ft.lbs / 5.4 Nm Torque @ 6000 RPM Cooling System Air cooled Oil Warning Low Oil Indicator Lubrication Oil Injection Oil Requirements / Capacity Polaris 2-cycle oil 20 oz / .6 Liter Exhaust System Single pipe Fuel System Carburetor model Sunworld H68K Main Jet 75 Pilot Jet 30 Pilot Air Jet 2.5 Jet Needle - Clip Position H68A-3 Needle/Seat 1.2mm Viton Pilot Screw 3/4 ± 1/4 Float Height Parallel to surface ± 1.0 mm Fuel Delivery Gravity Feed Fuel Capacity / Requirement 1 Gallon / 3.8 Liters 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 70 Watts @ 4000 RPM Voltage Regulator 14.5 VDC/5.5 A @ 4000 RPM Lights : Brake 18 watts Tail 8.26 watts Low Oil 1 watt Ignition System CDI Ignition Ignition Timing 17° @ 5000 RPM Spark plug / Gap BPR7HS/ .036 in. / 0.9 mm Battery / Model / Amp Hr Low Maintenance GTX5L-BS, 4.85 amp Circuit Breakers 7.5 Amp main fuse Starting Electric/Kick Start Instrument Cluster N/A Table 1-3: A06KA05CA Specifications Drivetrain Transmission Type Integrated - Fwd only Transmission Capacity / Type 10oz. / 296ml Polaris AGL Gearcase Lube Gear Ratio / Final Drive 15/35 - #428 Chain 58P Clutch Type Automatic C.V.T. System Belt 0450239 Steering / Suspension Front Suspension LH/RH control arm w/shock Front Travel 3″ (7.62cm) Rear Suspension Single Shock/Swing Arm Rear Travel 3″ (7.62cm) Shock Preload Adjustment Front / Rear Front - Non adjustable Rear - Cam-style Turning Radius 60″ / 152 cm Toe Out 1/8-1/4- in / 3-6 mm Wheels / Brakes Wheel Size / Pattern - Front 16x8–7 - 4/110mm Wheel Size / Pattern - Rear 16x8–7 - 4/110mm Front Tire Model / Size 16x8–7 Rear Tire Model / Size 16x8–7 Recommended Air Pressure Front - 2 psi / Rear - 2 psi Brake - Front Drum Brake - Rear Drum Table 1-4: A06KA05CA Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters (Feet) 0-1800 (0-6000) 6x14.5 Std Std Std. 1800-3700 (6000-12000) (Optional) 3x14.5 Std Std Std Table 1-5: A06KA05CA Jetting Altitude AMBIENT TEMPERATURE Below 40°F Below 5°C Above 40°F Above 5°C Meters (Feet) 0-1800 (0-6000) 75 75 1800-3700 (6000-12000) n/a n/a

1.5 GENERAL INFORMATION 2006 PREDATOR 90 SPECIFICATIONS MODEL NUMBER: A06KA09CA ENGINE MODEL: AR07-01 Table 1-6: Catagory Dimension / Capacity Length 57 in. / 145cm Width 35.75 in. / 91cm Height 36.1 in. / 91.8cm Wheel Base 38.5 in. / 98 cm Ground Clearance 5 in. / 12.7 cm Dry Weight 230 lbs. / 104 kg Gross Vehicle Weight 380 lbs./172 kg Rider Capacity 150 lbs. / 68 kg

1.6 GENERAL INFORMATION Table 1-7: A06KA09CA Specifications Engine Platform 2–Stroke Horizontal Engine Model Number AR07-01 Engine Displacement 89.2 cc Number of Cylinders 1 Bore & Stroke (mm) 2.05x1.65″ / 52x42 mm Compression Ratio 7.7:1 Compression Pressure 83 PSI / 5.8 kgf/cm2 Engine Idle Speed 1200 RPM ± 200 Engine Max Operating Rpm 6.5 ft.lbs / 8.82 Nm Torque @ 6000 RPM Cooling System Air cooled w/ fan assist Oil Warning Low Oil Indicator Lubrication Oil Injection Oil Requirements / Capacity Polaris 2-cycle oil 1.1 qt / 1 Liter Exhaust System Single pipe Fuel System Carburetor model Sunworld H68K Main Jet 82.5 Pilot Jet 25 Pilot Air Jet 2.5 Jet Needle - Clip Position E-3 Needle/Seat 1.5mm Viton Pilot Screw 7/8 ± 1/4 Float Height Parallel to surface ± 1.0 mm Fuel Delivery Gravity Feed Fuel Capacity / Requirement 1.3 Gallon / 5 Liters 87 Octane (minimum) 89 Oxygenated Electrical Alternator Output 70 Watts @ 5000 RPM Voltage Regulator 14.5 VDC/5.5 A @ 5000 RPM Lights : Brake 18 watts Tail 8.26 watts Low Oil / Reverse 1 watt Ignition System CDI Ignition Ignition Timing 18° @ 5000 RPM Spark plug / Gap BPR7HS/ .036 in. / 0.9 mm Battery / Model / Amp Hr Low Maintenance GTX5L-BS, 4.85 amp Circuit Breakers 7.5 Amp main fuse Starting Electric/Kick Start Instrument Cluster N/A Table 1-8: A06KA09CA Specifications Drivetrain Transmission Type Integrated : Fwd - Neutral - Rev Transmission Capacity Refill Capacity Type 20.25oz. / 600ml 16.25oz. / 480ml Polaris AGL Gearcase Lube Gear Ratio / Final Drive 19/41 - #428 Chain 88 Pitch Clutch Type Automatic C.V.T. System Belt 0450239 Steering / Suspension Front Suspension LH/RH control arm w/shock Front Travel 4.25″ / 10.8cm Rear Suspension Single Shock/Swing Arm Rear Travel 4.25″ / 10.8cm Shock Preload Adjustment Front / Rear Front - Cam-style Rear - Cam-style Turning Radius 76″ / 193 cm Toe Out 1/8-1/4- in / 3-6 mm Wheels / Brakes Wheel Size / Pattern - Front 19x7–8 - 4/110mm Wheel Size / Pattern - Rear 18x9.5–8 - 4/110mm Front Tire Model / Size 19x7–8 Rear Tire Model / Size 18x9.5–8 Recommended Air Pressure Front - 3 psi / Rear - 3 psi Brake - Front Drum Brake - Rear Drum Table 1-9: A06KA09CA Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters (Feet) 0-1800 (0-6000) 6x14.5 Std Std Std. 1800-3700 (6000-12000) (Optional) 3x14.5 Std Std Std Table 1-10: A06KA09CA Jetting Altitude AMBIENT TEMPERATURE Below 40°F Below 5°C Above 40°F Above 5°C Meters (Feet) 0-1800 (0-6000) 82.5 82.5 1800-3700 (6000-12000) n/a n/a

1.7 GENERAL INFORMATION 2006 SPORTSMAN 90 SPECIFICATIONS MODEL NUMBER: A06FA09CA ENGINE MODEL: AR07-01 Table 1-11: A06FA09CA Catagory Dimension / Capacity Length 59.75 in. / 151.8 cm Width 35.75 in. / 91 cm Height 36.6 in. / 93 cm Wheel Base 38.5 in. / 98 cm Ground Clearance 5 in./ 12.7 cm Dry Weight 238 lbs. / 108 kg Gross Vehicle Weight 418 lbs. / 189.6 kg Front Rack Capacity 10 lbs. / 4.54 kg Rear Rack Capacity 20 lbs. / 9.08 kg Rider Capacity 150 lbs. / 68 kg

1.8 GENERAL INFORMATION Table 1-12: A06FA09CA Specifications Engine Platform 2–Stroke Horizontal Engine Model Number AR07-01 Engine Displacement 89.2 cc Number of Cylinders 1 Bore & Stroke (mm) 2.05x1.65″ / 52x42 mm Compression Ratio 7.7:1 Compression Pressure 83 PSI / 5.8 kgf/cm2 Engine Idle Speed 1200 RPM ± 200 Engine Max Operating Rpm 6.5 ft.lbs / 8.82 Nm Torque @ 6000 RPM Cooling System Air cooled w/ fan assist Oil Warning Low Oil Indicator Lubrication Oil Injection Oil Requirements / Capacity Polaris 2-cycle oil 1.1 qt / 1 Liter Fuel System Carburetor model Sunworld H68K Main Jet 82.5 Pilot Jet 25 Pilot Air Jet 2.5 Jet Needle - Clip Position E-3 Needle/Seat 1.5mm Viton Pilot Screw 7/8 ± 1/4 Float Height Parallel to surface ± 1.0 mm Fuel Delivery Gravity Feed Electrical Alternator Output 70 Watts @ 5000 RPM Voltage Regulator 14.5 VDC/5.5 A @ 5000 RPM Lights : Brake 18 watts Tail 8.26 watts Low Oil / Reverse 1 watt Ignition System CDI Ignition Ignition Timing 18° @ 5000 RPM Spark plug / Gap BPR7HS/ .036 in. / 0.9 mm Battery / Model / Amp Hr Low Maintenance GTX5L-BS, 4.85 amp Circuit Breakers 7.5 Amp main fuse Starting Electric/Kick Start Instrument Cluster N/A Alternator Output 70 Watts @ 5000 RPM Table 1-13: A06FA09CA Specifications Drivetrain Transmission Type Integrated - Fwd only Transmission Capacity Refill Capacity Type 20.25oz. / 600ml 16.25oz. / 480ml Polaris AGL Gearcase Lube Gear Ratio / Final Drive 19/41 - #428 Chain 88P Clutch Type Automatic C.V.T. System Belt 0450239 Steering / Suspension Front Suspension LH/RH control arm w/shock Front Travel 4.25″ / 10.8cm Rear Suspension Single Shock/Swing Arm Rear Travel 4.25″ / 10.8cm Shock Preload Adjustment Front / Rear Front - Cam-style Rear - Cam-style Turning Radius 76″ / 193 cm Toe Out 1/8-1/4- in / 3-6 mm Wheels / Brakes Wheel Size / Pattern - Front 19x7–8 - 4/110mm Wheel Size / Pattern - Rear 18x9.5–8 - 4/110mm Front Tire Model / Size 19x7–8 Rear Tire Model / Size 18x9.5–8 Recommended Air Pressure Front - 3 psi / Rear - 3 psi Brake - Front Drum Brake - Rear Drum Table 1-14: A06FA09CA Clutching Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters (Feet) 0-1800 (0-6000) 6x14.5 Std Std Std. 1800-3700 (6000-12000) (Optional) 3x14.5 Std Std Std Table 1-15: A06FA09CA Jetting Altitude AMBIENT TEMPERATURE Below 40°F Below 5°C Above 40°F Above 5°C Meters (Feet) 0-1800 (0-6000) 82.5 82.5 1800-3700 (6000-12000) n/a n/a

1.9 GENERAL INFORMATION MISC. NUMBERS/CHARTS PUBLICATIONS PAINT CODES REPLACEMENT KEYS Replacement keys cannot be made from the original key. Should both keys become lost, ignition switch replacement is required. Table 1-16: Publications Year Model Model No. Owner's Manual PN Parts Manual PN Parts Micro Fiche PN 2006 Predator 50 A06KA05CA 9920229 9920235 9920236 2006 Predator 90 A06KA09CA 9920229 9920239 9920240 2006 Sportsman 90 A06FA09CA 9920229 9920239 9920240 Table 1-17: Paint Codes PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Springs - Sportsman 90 Black 9440 P-067 Frame - Predator 90 Silver -- P-385 Springs - Predator 50/90 Indy Red n/a P-293 Frame - All Gloss Black 9440 P-067

1.10 GENERAL INFORMATION STANDARD TORQUE SPECIFICATIONS The following torque specifications are to be used as a general guideline. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views in each manual section for torque values of fasteners before using standard torque.

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2006 POLARIS Predator 50, Outlaw 90, Sportsman 90 YOUTH 4 Stroke Service Repair Shop Manual

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