2005 Polaris Predator 50/Predator 90/Sportsman 90 ATVs OEM Service & Repair Manual

2005 PREDATOR 50 2005 PREDATOR 90 2005 SPORTSMAN 90 SERVICE MANUAL PN 9919532 2005 YOUTH ATV SERVICE MANUAL PN 9919532

2005 Predator 50, Predator 90, Sportsman 90 SERVICE MANUAL Foreword This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified. This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 2005 Polaris Predator 50, Predator 90, and Sportsman 90. Comments or suggestions about this manual may be directed to: Service Publications Dept. @ Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340. Some Polaris factory manuals can be downloaded from www.polarisindustries.com or purchased from www.purepolaris.com or contact your nearest Polaris dealer. 2005 Polaris Youth ATV Service Manual (PN 9919532) ECopyright 2004 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvement in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.

UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS Throughout these instructions, important information is brought to your attention by the following symbols: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! DANGER Failure to follow DANGER instructions will result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. WARNING Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or person inspecting or servicing the ATV. CAUTION: A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property damage. NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: Loctite, Registered Trademark of the Loctite Corporation Nyogel, Trademark of Wm. F. Nye Co. Fluke, Registered Trademark of John Fluke Mfg. Co. Mity Vac, Registered Trademark of Neward Enterprises, Inc.

CHAPTER INDEX CHAPTER 1 GENERAL/MAINTENANCE CHAPTER 2 ENGINE/TRANSMISSION CHAPTER 3 FUEL SYSTEM CHAPTER 4 BODY/SUSPENSION CHAPTER 5 ELECTRICAL

GENERAL INFORMATION 1.1 Model I.D. / Serial Number Location 1.2 ........ 2005 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 ....... 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 05 KA 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 * 5 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 2005 YOUTH MODEL A TVS PREDATOR 50 SPORTSMAN 90 PREDATOR 90 NOTE: Model colors may vary.

GENERAL INFORMATION 1.4 MODEL: 2005 PREDATOR 50 .......... MODEL NUMBER: A05KA05CA . 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 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 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: 2005 PREDATOR 90 .......... MODEL NUMBER: A05KA09CA . 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 / 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 Drivetrain Transmission Type Integrated -- Fwd only Transmission Capacity / Type 10oz. / 296ml 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 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: 2005 SPORTSMAN 90 .......... MODEL NUMBER: A05FA09CA . 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 / 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 Drivetrain Transmission Type Integrated -- Fwd only Transmission Capacity / Type 10oz. / 296ml 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 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

2005 Polaris Predator 50/Predator 90/Sportsman 90 ATVs OEM Service & Repair Manual

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