Polaris Outlaw 90 2011 Factory Service & Work Shop Manual

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: 2009 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2009 OUTLAW 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2009 SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 MODEL: 2009 PREDATOR 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 MODEL: 2009 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 0 9 K A 0 9 AB } R F 3 K A 0 9 A * 9 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.....................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 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: 2009 PREDATOR 50 MODEL #: A09KA05AB, 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: 2009 OUTLAW / SPORTSMAN 90 OUTLAW MODEL #: A09KA09AB, AD SPORTSMAN MODEL #: A09FA09AA, 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 2009 Predator 50 A09KA05AB, AD 9921811 9921812 2009 Outlaw 90 A09KA09AB, AD 9921796 9921815 2009 Sportsman 90 A09FA09AA, 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

Polaris Outlaw 90 2011 Factory Service & Work Shop Manual

You're Reading a Preview

Recently Viewed