GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2010 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2010 OUTLAW 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2010 SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
MODEL: 2010 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2010 OUTLAW / SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MISCELLANEOUS INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SPECIAL TOOLS - WHERE USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
STANDARD TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
1.2
GENERAL INFORMATION
MODEL INFORMATION
Model Identification
The machine model number must be used with any correspondence regarding warranty or service.
Engine Designation Numbers
50cc Model: M10A - Single Cylinder, Air Cooled, SOHC, 4-Stroke, Electric Start
90cc Model: H18S - Single Cylinder, Air Cooled, SOHC, 4-Stroke, Electric Start
VIN Identification
Engine Serial Number Location
Whenever corresponding about an engine, be sure to refer to the engine serial number. This information can be found stamped on
the top LH side of the crankcase as shown below.
Vehicle Identification Number Location
The vehicle identification number (VIN) and engine serial number are important for identification purposes. See the illustrations
below as a location reference.
}
Machine Model Number Identification
}
}
Year Designation
Basic Chassis
Designation
Engine Designation
Emissions &
Model Option
A 10 K A 0 9 AB
}
4 X A K A 0 9 A * 0 P 0 0 0 0 0 0
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Descriptor Vehicle Identifier
Check Digit
Model
Year
Body Style
Plant No
Individual Serial Number
* This could be either a number or a letter
Powertrain
Emissions
Predator 50
VIN
Engine Serial Number
VIN
Engine Serial Number
Sportsman 90 / Outlaw 90
1.3
GENERAL INFORMATION
1
GENERAL SPECIFICATIONS
MODEL.....................2010 PREDATOR 50
MODEL NUMBER.............A10KA05AB, AD
ENGINE MODEL..................M10A
MODEL.........................2010 OUTLAW 90
MODEL NUMBER.............A10KA09AB, AD
ENGINE MODEL..................H18S
MODEL..................2010 SPORTSMAN 90
MODEL NUMBER.............A10FA09AA, AB
ENGINE MODEL..................H18S
Category Dimension
Length 48 in. / 122 cm
Width 31.5 in. / 80 cm
Height 28 in. / 71 cm
Wheel Base 33 in. / 84 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 90 lbs. / 41 kg
Dry Weight 185 lbs. / 84 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 1.2 gal / 4.5L
Category Dimension
Length 61.25 in. / 156 cm
Width 36.75 in. / 93 cm
Height 38.5 in. / 98 cm
Wheel Base 41.5 in. / 105 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 170 lbs. / 77 kg
Dry Weight 283 lbs. / 128 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 1.7 gal. / 6.4 L
Category Dimension
Length 61.75 in. / 157 cm
Width 36.75 in. / 93 cm
Height 38.5 in. / 98 cm
Wheel Base 41.5 in. / 105 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 170 lbs. / 77 kg
Dry Weight 305 lbs. / 138 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 2 gal. / 7.7 L
Front Rack Capacity 15 lbs. / 6.8 kg
Rear Rack Capacity 30 lbs. / 13.6 kg
1.4
GENERAL INFORMATION
MODEL: 2010 PREDATOR 50
MODEL #: A10KA05AB, AD
ENGINE MODEL: M10A
Engine
Platform Aeon SOHC 4-Stroke
Engine Displacement 49.5cc
Number of Cylinders 1
Bore & Stroke (mm) 39 x 41.4 mm
Compression Ratio 9.2:1
Compression Pressure 115-155 psi
Engine Idle Speed 1500 ± 100 RPM
Cooling System Air Cooled
Overheat Warning n/a
Lubrication Oil Pump Pressurized Wet Sump
Oil Requirements
Polaris SAE 40 (Above 32°F)
Polaris 20W-40 (Below 32°F)
30 oz. (900 ml)
Exhaust System USFS Approved
Carburetion
Carburetor Model Mikuni VM12H
Main Jet 62
Pilot Jet 12.5
Jet Needle 3X6-4
Needle Jet n/a
Throttle Valve Cutaway n/a
Inlet Valve Seat Size 1.2
Pilot / Air Screw
2.5 Turns Out
(Initial setting, varies by ATV)
Float Height Parallel To Float Bowl
Fuel Delivery Gravity Feed System
Fuel Capacity 1.2 gal. (4.5 L)
Fuel Reserve Capacity 0.22 gal. (0.85 L)
Electrical
Alternator Output 56 Watts @ 1700 RPM
Voltage Regulator Single Phase / Full Wave
Daytime Running Lights 15 Watts
Brake Light 21 watts
Tail Light 5 watts
Ignition System CDI Ignition
Ignition Timing 17.5 BTDC @ 1700 RPM
Spark plug / Gap
NGK CR6HSA
.024 - .028 in./ .6-.7 mm
Battery / Model / Amp Hr Low Maintenance / 12V / 5 AH
Fuses (1) 7 Amp
Starting Electric / Kick Start Backup
Indicator Panel n/a
Drivetrain
Transmission Type Forward Gear Only
Transmission Lubricant
Capacity
11.8 oz. (350 ml) or to bottom
of fill hole threads
Drive Type Chain
Clutch Type Automatic CVT
Drive Belt 0453455
Steering / Suspension
Front Suspension Style
Single Control Arm /
Non-Adjust Shocks
Front Travel 3 in. / 7.6 cm
Rear Suspension Style
Mono Shock Swingarm /
Cam Adjust Shock
Rear Travel 3 in. / 7.6 cm
Ground Clearance 4 in. / 10 cm
Shock Preload Adjustment Rear - Cam Adjust
Toe Out 1/8 in. - 1/4 in / 3 - 6 mm
Wheels / Brakes
Tire Size / Bolt Pattern - Front 16 x 6.5 - 7 / 4-110
Tire Size / Bolt Pattern - Rear 16 x 8 - 7 / 4-110
Air Pressure - F/R Tires 2 psi (13.8 KPa)
Brakes - Front / Rear Drum
Parking Brake Mechanical Lock
1.5
GENERAL INFORMATION
1
MODEL: 2010 OUTLAW / SPORTSMAN 90
OUTLAW MODEL #: A10KA09AB, AD
SPORTSMAN MODEL #: A10FA09AA, AB
ENGINE MODEL: H18S
Engine
Platform Aeon SOHC 4-Stroke
Engine Displacement 89.9cc
Number of Cylinders 1
Bore & Stroke (mm) 47 x 51.8 mm
Compression Ratio 9.2:1
Compression Pressure 115-155 psi
Engine Idle Speed 1700 ± 100 Rpm
Cooling System Air Cooled
Overheat Warning n/a
Lubrication Oil Pump Pressurized Wet Sump
Oil Requirements
Polaris SAE 40 (Above 32°F)
Polaris 20W-40 (Below 32°F)
30 oz. (900 ml)
Exhaust System USFS Approved
Carburetion
Carburetor model Keihin PTE16
Main Jet 82
Pilot Jet 40
Jet Needle 89Q - 3 clip
Needle Jet 11
Throttle Valve Cutaway 3.0 SA
Pilot / Air Screw
2.25 ± .5 Turns Out
(Initial setting, varies by ATV)
Float Height Parallel To Float Bowl
Fuel Delivery Gravity Feed System
Fuel Capacity
1.7 gal. (6.4 L) - Outlaw 90
2 gal. (7.7 L) - Sportsman 90
Fuel Reserve Capacity
0.23 gal. (0.86 L) - Outlaw 90
0.22 gal. (0.85 L) - Sportsman 90
Electrical
Alternator Output 56 Watts @ 1700 RPM
Voltage Regulator Single Phase / Full Wave
Daytime Running Lights 15 Watts
Brake Light 21 watts
Tail Light 5 watts
Ignition System CDI Ignition
Ignition Timing 17.5 BTDC @ 1700 RPM
Spark plug / Gap
NGK CR6HSA
.024 - .028 in./ .6-.7 mm
Battery / Model / Amp Hr Low Maintenance / 12V / 5 AH
Fuses (1) 7 Amp
Starting Electric / Kick Start Backup
Indicator Panel Neutral / Reverse
Drivetrain
Transmission Type Integrated F/N/R
Transmission Lubricant
Capacity
11.8 oz. (350 ml) or to bottom
of fill hole threads
Drive Type Chain
Clutch Type Automatic CVT
Drive Belt 0453455
Steering / Suspension
Front Suspension Style
Single A-arm /
Cam Adjust Shocks
Front Travel 5 in. / 12.7 cm
Rear Suspension Style
Mono Shock Swingarm /
Cam Adjust Shock
Rear Travel 6 in. / 15.2 cm
Ground Clearance 4 in. / 10 cm
Shock Preload Adjustment
Front - Cam Adjust
Rear - Cam Adjust
Toe Out 1/8 in. - 1/4 in / 3 - 6 mm
Wheels / Brakes
Tire Size / Bolt Pattern - Front 19 x 7 - 8 / 4-110
Tire Size / Bolt Pattern - Rear 18 x 9.5 - 8 / 4-110
Air Pressure - F/R Tires 3 psi (20.7 KPa)
Brakes - Front / Rear Drum
Parking Brake Mechanical Lock
1.6
GENERAL INFORMATION
MISCELLANEOUS INFORMATION
Publication Numbers
NOTE: When ordering service parts be sure to use the correct parts manual.
NOTE: Some manuals can be found at the Polaris website: www.polarisindustries.com or purchased from
www.purepolaris.com.
Paint Codes
Replacement Keys
Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut to match the
original. Should both keys become lost, ignition switch replacement is required.
Year Model Model No. Owner’s Manual PN Parts Manual PN
2010 Predator 50 A10KA05AB, AD 9921811 9921812
2010 Outlaw 90 A10KA09AB, AD 9921796 9921815
2010 Sportsman 90 A10FA09AA, AB 9921796 9921797
Painted Part Color Description Polaris Number
Frame / Swing Arm Medium Gloss Black P-067
Frame / Swing Arm Cloud Silver P-385
Key Blank
0453013
1.7
GENERAL INFORMATION
1
Special Tools - Where Used
Special Tools may be required to service this ATV. Some of the tools listed are mandatory, while other tools may be substituted with
a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product.
NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog or by calling
SPX @ 1-800-328-6657.
PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN
2870872 Shock Spanner Wrench 2, 5
PV-39951-A Tachometer 2, 8
PV-35667-A Cylinder Leakdown Tester 2, 3
2870390 Piston Support Block 3
PA-45153 Flywheel Puller 3
PA-46502 Valve Spring Compressor 3
PA-48701 Adaptor, Valve Spring Compressor 3
PV-26900-8 26 Blade Thickness Gauge (Feeler Gauge) 3
PA-47361 Carburetor Adjustment Screwdriver 4
2870975 Mity Vac™ Pressure Test Tool 4
2870623 Shock Absorber Spring Compression Tool 5
PV-63070 Christie Multi-Battery Charger 8
2870630 Timing Light 8
2870836 Battery Hydrometer 8
PV-43568 Fluke™73 Digital Multimeter 8
PV-39991 Peak Reading Adaptor 8
1.8
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.
1.9
GENERAL INFORMATION
1
Conversion Table
°C to °F:
9/5
(°C + 32) = °F
°F to °C:
5/9
(°F - 32) = °C
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 = mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 = Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
p(3.14)xR2x H (height) = Cylinder Volume
1.10
GENERAL INFORMATION
SAE Tap Drill Sizes
Metric Tap Drill Sizes
Decimal Equivalents
Thread Size / Drill Size Thread Size / Drill Size
#0-80 3/64 1/2-13 27/64
#1-64 53 1/2-20 29/64
#1-72 53 9/16-12 31/64
#2-56 51 9/16-18 33/64
#2-64 50 5/8-11 17/32
#3-48 5/64 5/8-18 37/64
#3-56 45 3/4-10 21/32
#4-40 43 3/4-16 11/16
#4-48 42 7/8-9 49/64
#5-40 38 7/8-14 13/16
#5-44 37 1-8 7/8
#6-32 36 1-12 59/64
#6-40 33 1 1/8-7 63/64
#8-32 29 1 1/8-12 1 3/64
#8-36 29 1 1/4-7 1 7/64
#10-24 24 1 1/4-12 1 11/64
#10-32 21 1 1/2-6 1 11/32
#12-24 17 1 1/2-12 1 27/64
#12-28 4.6mm 1 3/4-5 1 9/16
1/4-20 7 1 3/4-12 1 43/64
1/4-28 3 2-4 1/2 1 25/32
5/16-18 F 2-12 1 59/64
5/16-24 I 2 1/4-4 1/2 2 1/32
3/8-16 O 2 1/2-4 2 1/4
3/8-24 Q 2 3/4-4 2 1/2
7/16-14 U 3-4 2 3/4
7/16-20 25/64
Tap Size Drill Size
Decimal
Equivalent
Nearest
Fraction
3x.50 #39 0.0995 3/32
3x.60 3/32 0.0937 3/32
4x.70 #30 0.1285 1/8
4x.75 1/8 0.125 1/8
5x.80 #19 0.166 11/64
5x.90 #20 0.161 5/32
6x1.00 #9 0.196 13/64
7x1.00 16/64 0.234 15/64
8x1.00 J 0.277 9/32
8x1.25 17/64 0.265 17/64
9x1.00 5/16 0.3125 5/16
9x1.25 5/16 0.3125 5/16
10x1.25 11/32 0.3437 11/32
10x1.50 R 0.339 11/32
11x1.50 3/8 0.375 3/8
12x1.50 13/32 0.406 13/32
12x1.75 13/32 0.406 13/32
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Polaris Outlaw 90 2009 2010 Workshop Service Manual
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Description
The Polaris Outlaw 90 2009 2010 Workshop Service Manual for Repair is available for instant access, eliminating shipping costs and waiting time. This manual is designed for both professional mechanics and DIY enthusiasts, providing comprehensive data, characteristics, instructions, and methodology for performing repair interventions on the vehicle and its components.
Key features of this manual include:
- Printable pages
- File Format: .PDF
- Language: English
- Compatibility: Windows/ Mac and Linux OS
- Comprehensive step-by-step procedures, explanations, and pictorial diagrams
- Special notes, important points, service data, precautions, etc.
- Detailed illustrations, exploded diagrams, drawings, and photos
- Reference to service tool numbers and wear limits
This service manual is intended to be a handy, easy-to-read reference book, providing detailed explanations of installation, removal, disassembly, assembly, repair, and check procedures in sequential order. It is suitable for viewing on any computer, allowing zooming and printing for convenience.
Additionally, the manual includes general descriptions for accomplishing service and repair work with tested, effective techniques, ensuring reliability and maximum customer satisfaction. It also provides information on construction, function, troubleshooting, servicing specifications, and safety measures.
To maximize the life of the Polaris Outlaw 90 2009 2010, it is essential to follow the maintenance requirements, investigate and rectify problems promptly, use genuine parts, and adhere to the procedures outlined in the manual. Complete records of all maintenance and repairs should be maintained, and only approved lubricants should be used.
This manual is designed to provide technical information, adjustment values, and reference data for maintenance and repair work on the Polaris Outlaw 90 2009 2010. It is suitable for trained technicians in a workshop setting as well as owners with the necessary tools and knowledge of mechanics to perform basic maintenance and repair work.
For all maintenance and repair work, strict observance of accident prevention guidelines is necessary, and the required safety measures are outlined in the manual. The manual also emphasizes the importance of using the correct tools, following torque specifications, and observing safety precautions.
Overall, the Polaris Outlaw 90 2009 2010 Workshop Service Manual for Repair is a comprehensive, quality resource for servicing and repairing the vehicle using safe, effective methods, ensuring the vehicle remains in optimum condition.
