Polaris Predator 50 / Outlaw 90 / Sportsman 90 service manual 2004

GENERAL INFORMATION 1.1 Model I.D. / Serial Number Location 1.2 ........ 2004 Youth Models 1.3 ....................... Specifications 1.4--1.6 ............................ Publication Numbers 1.7 ..................... Paint Codes 1.7 ............................. Inspection Schedule 1.7--1.9 ...................... Standard Torque Specifications 1.10 ............ Special Tools 1.10 ............................ Lubricant and Maintenance Products 1.10 ....... 2004 Speed Limiter System Overview 1.11 ...... Vehicle Inspection/Adjustments 1.12--1.14 ............ Transmission Lubrication 1.15 .................. Throttle Operation / Idle -- Air Screw Adjust. 1.16 . Throttle Cable / ETC Adjustments 1.17 .......... Oil Pump Adjustment / Bleeding 1.18 ............ Oil Pump Troubleshooting 1.19 ................. Fuel System 1.19--1.20 ............................ Compression Test 1.21 ........................ Air Filter Service 1.21 ......................... Spark Plug 1.21 .............................. Wheels and Tires 1.21--1.22 ........................ Steering / Alignment 1.23--1.24 ...................... Glossary of Terms 1.25 ........................ Unit of Measure Conversion Table 1.26 .......... Tap Drill Charts 1.27 .......................... Decimal Equivalent Chart 1.27 ................. &

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation A 04 EA 05 CA Emissions & Model Option VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 R F 3 E A 0 5 C * 4 T 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter SERIAL NUMBER LOCA TIONS Whenever corresponding about an engine, be sure to refer to the engine serial number. This information can be found stamped on the transmission section located by the transmission oil fill plug(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). Front B A

GENERAL INFORMATION 1.3 2004 YOUTH MODEL A TVS PREDATOR 50 SPORTSMAN 90 PREDATOR 90 NOTE: Model colors may vary.

GENERAL INFORMATION 1.4 MODEL: 2004 PREDATOR 50 .......... MODEL NUMBER: A04KA05CA . ENGINE MODEL: AR03 .. 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 Carburetion 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 Drivetrain Transmission Type Integrated -- Fwd only Transmission Capacity / Type 10oz. / 296ml Polaris Angle Drive Fluid 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 -- 2psi/ Rear -- 2psi Brake -- Front Drum Brake -- Rear Drum General Weights / Measurements Overall Dimensions LxWxH 48x31.5x28″ 122x80x71cm Seat Height 22.5″ / 57 cm Dry Weight 185 lbs. / 84 kg Rider Capacity / Max Weight 90 lbs. / 40.8 kg Wheel Base 33″ / 84 cm Ground Clearance 4″ / 8 cm

GENERAL INFORMATION 1.5 MODEL: 2004 PREDATOR 90 .......... MODEL NUMBER: A04KA09CA . ENGINE MODEL: AR07 .. 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 Carburetion 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 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 Drivetrain Transmission Type Integrated -- Fwd only Transmission Capacity / Type 10oz. / 296ml Polaris Angle Drive Fluid 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 -- Non adjustable 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 -- 3psi/ Rear -- 3psi Brake -- Front Drum Brake -- Rear Drum General Weights / Measurements Overall Dimensions LxWxH 57x35.75x36.1″ 145x91x91.8cm Seat Height 22.5″ / 57 cm Dry Weight 230 lbs. / 104 kg Rider Capacity / Max Weight 150 lbs. / 68 kg Wheel Base 38.5″ / 98 cm Ground Clearance 5″ / 12.7 cm

GENERAL INFORMATION 1.6 MODEL: 2004 SPORTSMAN 90 .......... MODEL NUMBER: A04FA09CA . ENGINE MODEL: AR07 .. 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 Carburetion 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 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 Drivetrain Transmission Type Integrated -- Fwd only Transmission Capacity / Type 10oz. / 296ml Polaris Angle Drive Fluid 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 -- Non adjustable 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 -- 3psi/ Rear -- 3psi Brake -- Front Drum Brake -- Rear Drum General Weights / Measurements Overall Dimensions LxWxH 59.75x35.75x36.6″ 151.8x91x93cm Seat Height 24.5″ / 62 cm Dry Weight 238 lbs. / 108 kg Rider Capacity / Max Weight 150 lbs. / 68 kg Front Rack Capacity 10 lbs. / 4.54 kg Rear Rack Capacity 20 lbs. / 9.08 kg Wheel Base 38.5″ / 98 cm Ground Clearance 5″ / 12.7 cm

GENERAL INFORMATION 1.7 NOTE: * Check owner’s manual for loading requirements and restrictions.** Specification is reference only -- not adjustable. PUBLICATION NUMBERS Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN Sportsman 90 A04FA09CA 9918778 9918780 9918781 Predator 50 A04KA05CA 9918778 9919132 9919133 Predator 90 A04KA09CA 9918778 9918313 9918314 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER Sportsman 90 Springs Medium Gloss Black 9440 P-067 Predator 50/90 Springs Indy Red N/A P-293 Frame -- All Medium Gloss Black 9440 P-067 Order direct from Midwest Industrial Coatings (952-242-2000). PERIODIC MAINTENANCE SCHEDULE Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Maintenance Chart Key " Perform these operations more often under severe use, such as in dirty or wet conditions, to purge water or dirt contamination from grease fittings and other critical components. J Dealer service item. (Maintenance chart -- next page) Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Only authorized Polaris dealers should perform these services. WARNING

GENERAL INFORMATION 1.8 Periodic Maintenance Schedule Item to Inspect Hours/ Miles Frequency Remarks Brake System Pre-ride Pre-ride Inspect Tires Pre-ride Pre-ride Inspect Wheels Pre-ride Pre-ride Inspect Frame nuts, bolts, fasteners Pre-ride Pre-ride Inspect; tighten any loose hardware Throttle Pre-ride Pre-ride Check for proper operation Engine stop switch Pre-ride Pre-ride Check for proper operation Engine oil Pre-ride Pre-ride Check level; fill oil when refueling " Air Filter Pre-ride Pre-ride Inspect; clean " Steering Pre-ride Pre-ride Check for free operation " Drive Chain Pre-ride Pre-ride Inspect J Brake pad wear 10 hrs Monthly Inspect periodically Battery 20 hrs Monthly Inspect terminals; clean Oil Pump Cable 50 hrs 6 months Inspect; adjust; lubricate; replace if required Carburetor Float Bowl 50 hrs 6 months Drain bowl periodically and prior to storage Spark Plug 100 hrs 12 months Inspect; replace if necessary J Ignition Timing 100 hrs 12 months Inspect; adjust as needed J Fuel System 100 hrs 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years. J Fuel Filter 100 hrs 12 months Replace annually J Front wheel bearings 300 hrs 36 months Inspect; replace if necessary J Idle Speed As needed As needed Adjust J Toe adjustment As needed As needed Inspect periodically adjust when parts are replaced J Throttle Cable/ETC Switch 50 hrs 6 months Inspect; adjust; lubricate; replace if necessary " Steering 50 hrs 6 months Inspect; lubricate " Rear Axle 50 hrs 6 months Inspect bearings; lubricate " Drive Chain 50 hrs 6 months Inspect; adjust and lubricate if needed " Front Suspension 50 hrs 6 months Inspect; lubricate; tighten fasteners " Rear Suspension 50 hrs 6 months Inspect; tighten fasteners J Clutches (drive and driven) 100 hrs 12 months Inspect; clean Engine Mounts 100 hrs 12 months Inspect J Cylinder Head 25 hrs -- -- Retorque cylinder head after the first 25 hours of operation

GENERAL INFORMATION 1.9 LUBRICA TION 1. Lubricate grease fittings monthly with Polaris All Season Grease. Lubricate more frequently if riding often in water, sand, mud, etc. Polaris Premium All Season Grease 14 oz. (PN 2871423) Grease Gun Kit PN 2871312 Lubrication Recommendations Item Lube Method Frequency 1. Engine Oil Polaris VES II Synthetic 2-cycle Fill oil tank. See Page 1.20. As needed and when refueling 2.. Gearcase Oil Level AGL Synthetic gearcase lube See Page 1.15. Change annually or at 100 hrs. Maintain in SAFE range. 3. Drive Chain Polaris chain lube or SAE 80/90 Lubricate as required and before each ride in wet conditions. As required 4.. Front A-Arm and spindles " L Grease Locate fittings and grease. Every 3 months or 50 hrs. ” Grease more often under severe use, such as wet or dusty conditions. L Use Polaris Premium all Season Grease or grease conforming to NLGI No. 2. 2. 4. 4. 50cc Models 90cc Models Gearcase Oil Level 50cc & 90cc

GENERAL INFORMATION 1.10 STANDARD T ORQUE SPECIFICA TIONS 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. FASTENER TORQUE (ft.lbs. / in.lbs.) TORQUE (Nm) 5 mm bolts and nuts 39-52 in.lbs. 4.5-6 Nm 6 mm bolts and nuts 69-104 in.lbs. 8-12 Nm 8 mm bolts and nuts 13-18 ft.lbs 18-25 Nm 10 mm bolts and nuts 22-29 ft.lbs. 30-40 Nm 12 mm bolts and nuts 36-43 ft.lbs. 50-60 Nm 4 mm screws 22-30 in.lbs. 2.5-3.4 Nm 5 mm screws 30-43 in.lbs. 3.5-5 Nm 6 mm Hex bolts 87-121 in.lbs. 10-14 Nm 8 mm Hex bolts 17-22 ft.lbs. 24-30 Nm 10 mm Hex bolts 25-32 ft.lbs. 35-45 Nm SPECIAL T OOLS DESCRIPTION PART NUMBER Flywheel Puller PA--45153 Crankcase/Crankshaft Separating Tool PA--46087 Shock Spanner Wrench 2870872 Battery Charger PV--37453 NOTE: Special tools can be ordered by Polaris Dealers only through SPX Corporation. POLARIS LUBRICANT AND MAINTENANCE PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil 2871098 Premium 2 Cycle Engine Oil (Quart) 2871097 Premium 2 Cycle Engine Oil (Gallon) 2871240 Premium 2 Cycle Engine Oil (2.5 Gallon) 2871566 Premium 2 Cycle Engine Oil (16 Gallon) 2871385 Premium 2 Cycle Engine Oil (30 Gallon) 2871240 Premium 2 Cycle Engine Oil (55 Gallon) 2871721 Premium Gold 2 Cycle Synthetic Lubricant (Quart) 2871722 Premium Gold 2 Cycle Synthetic Lubricant (Gallon) Gearcase / Transmission Lubricants 2873603 Polaris AGL Gearcase Lubricant (Gallon) 2873602 Polaris AGL Gearcase Lubricant (32 oz. bottle) 2870465 Oil Pump for Gearcase Oil Grease / Specialized Lubricants 2871322 Premium All Season Grease (3 oz.. cartridge) 2871423 Premium All Season Grease (14 oz.. cartridge) 2871460 Starter Drive Grease 2871312 Chain Lube (6.25 oz.) 2871312 Grease Gun Kit 2871329 Nyogelt Grease Additives / Sealants / Thread Locking Agents / Misc. 2871326 Carbon Clean 12 oz.. 2870652 Fuel Stabilizer 16 oz..

Polaris Predator 50 / Outlaw 90 / Sportsman 90 service manual 2004

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