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Polaris PREDATOR 50 2009 - User Manual

Polaris PREDATOR 50 2009
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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
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Table of Contents

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Overview

  1. Technical Specifications
  2. Predator 50
  3. Outlaw 90 / Sportsman 90
  4. Usage Features
  5. Maintenance Features

This manual describes the 2009 Polaris Predator 50, Outlaw 90, and Sportsman 90 youth ATVs. These vehicles are single-cylinder, air-cooled, SOHC, 4-stroke, electric start models.

Technical Specifications:

Predator 50:

  • Engine: M10A, Aeon SOHC 4-Stroke, 49.5cc displacement, 1 cylinder, 39 x 41.4 mm bore & stroke, 9.2:1 compression ratio (115-155 psi).
  • Dimensions: 48 in. (122 cm) length, 31.5 in. (80 cm) width, 28 in. (71 cm) height, 33 in. (84 cm) wheelbase, 4 in. (10 cm) ground clearance at swing arm.
  • Weight: 185 lbs. (84 kg) dry weight.
  • Capacities: 30 oz. (900 ml) oil capacity, 1.2 gal (4.5 L) fuel capacity, 0.22 gal (0.85 L) fuel reserve.
  • Carburetion: Mikuni VM12H, Main Jet 62, Pilot Jet 12.5, Jet Needle 3X6-4, Pilot/Air Screw 2.5 turns out.
  • Electrical: 56 Watts @ 1700 RPM alternator output, 15 Watts daytime running lights, 21 Watts brake light, 5 Watts tail light, CDI Ignition, 17.5° BTDC @ 1700 RPM ignition timing, NGK CR6HSA spark plug (.024-.028 in./.6-.7 mm gap), 12V/5 AH low maintenance battery, (1) 7 Amp fuse.
  • Drivetrain: Forward gear only transmission, chain drive, automatic CVT clutch, 0453455 drive belt. Transmission lubricant capacity: 11.8 oz. (350 ml).
  • Suspension: Single control arm / non-adjust shocks front (3 in./7.6 cm travel), mono shock swingarm / cam adjust shock rear (3 in./7.6 cm travel).
  • Wheels/Tires: Front 16 x 6.5 - 7 / 4-110, Rear 16 x 8 - 7 / 4-110, 2 psi (13.8 KPa) air pressure. Drum brakes front/rear, mechanical lock parking brake.

Outlaw 90 / Sportsman 90:

  • Engine: H18S, Aeon SOHC 4-Stroke, 89.9cc displacement, 1 cylinder, 47 x 51.8 mm bore & stroke, 9.2:1 compression ratio (115-155 psi for Outlaw, 135-175 psi for Sportsman).
  • Dimensions (Outlaw 90): 61.25 in. (156 cm) length, 36.75 in. (93 cm) width, 38.5 in. (98 cm) height, 41.5 in. (105 cm) wheelbase, 4 in. (10 cm) ground clearance at swing arm.
  • Dimensions (Sportsman 90): 61.75 in. (157 cm) length, 36.75 in. (93 cm) width, 38.5 in. (98 cm) height, 41.5 in. (105 cm) wheelbase, 4 in. (10 cm) ground clearance at swing arm.
  • Weight: 283 lbs. (128 kg) dry weight for Outlaw 90, 305 lbs. (138 kg) dry weight for Sportsman 90.
  • Capacities: 30 oz. (900 ml) oil capacity, 1.7 gal (6.4 L) fuel capacity for Outlaw 90, 2 gal (7.7 L) for Sportsman 90. Fuel reserve capacity: 0.23 gal (0.86 L) for Outlaw 90, 0.22 gal (0.85 L) for Sportsman 90.
  • Carburetion: 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.
  • Electrical: 56 Watts @ 1700 RPM alternator output, 15 Watts daytime running lights, 21 Watts brake light, 5 Watts tail light, CDI Ignition, 17.5° BTDC @ 1700 RPM ignition timing, NGK CR6HSA spark plug (.024-.028 in./.6-.7 mm gap), 12V/5 AH low maintenance battery, (1) 7 Amp fuse.
  • Drivetrain: Integrated F/N/R transmission, chain drive, automatic CVT clutch, 0453455 drive belt. Transmission lubricant capacity: 11.8 oz. (350 ml).
  • Suspension: Single A-arm / cam adjust shocks front (5 in./12.7 cm travel), mono shock swingarm / cam adjust shock rear (6 in./15.2 cm travel).
  • Wheels/Tires: Front 19 x 7 - 8 / 4-110, Rear 18 x 9.5 - 8 / 4-110, 3 psi (20.7 KPa) air pressure. Drum brakes front/rear, mechanical lock parking brake.
  • Rack Capacity (Sportsman 90 only): 15 lbs. (6.8 kg) front, 30 lbs. (13.6 kg) rear.

Usage Features:

  • Model Identification: Machine model number and VIN are crucial for warranty and service. Engine serial number is stamped on the top LH side of the crankcase. VIN is located as illustrated.
  • Speed Control System: Youth models have adjustable throttle limiting screws. Speed limiting devices can be adjusted/removed by consumers when the child is capable of handling additional speed.
  • Kick-Start Lever: Available for starting the engine if the battery is too weak.
  • Fuel System: Carburetor operation is detailed, including float, pilot, main, and starter systems. Fuel delivery and air/fuel mixture ratio are explained.
  • Ignition System: CDI controlled, non-adjustable timing.
  • CVT System: Consists of drive clutch, driven clutch, and drive belt. Controls engagement, upshift, and backshift.

Maintenance Features:

  • Periodic Maintenance Chart: Provides a schedule for inspections, adjustments, and lubrication based on average riding conditions. Severe use requires more frequent service.
  • Model Information: Includes publication numbers for owner's manuals and parts manuals.
  • Paint Codes: Polaris paint codes are provided for frame/swing arm (Medium Gloss Black P-067, Cloud Silver P-385).
  • Replacement Keys: Key blanks (0453013) are available. Ignition switch replacement is required if both keys are lost.
  • Special Tools: A list of special tools required for servicing the ATV is provided, including shock spanner wrench, tachometer, cylinder leakdown tester, piston support block, flywheel puller, valve spring compressor, carburetor adjustment screwdriver, Mity Vac™ pressure test tool, Christie Multi-Battery Charger, timing light, battery hydrometer, Fluke™73 Digital Multimeter, and peak reading adaptor.
  • Standard Torque Specifications: General guidelines for fastener torque values are provided, with exceptions noted for steering, suspension, and engine areas.
  • Conversion Table: Units of measure and conversion factors are provided.
  • Glossary of Terms: Explanations of technical terms used in the manual.
  • General Vehicle Inspection: Daily pre-ride inspection includes checking tires, fuel/oil levels, brakes, throttle, lights, engine stop switch, wheels, air cleaner, steering, and loose parts.
  • Fuel System and Air Intake: Safety precautions for handling gasoline, speed control system adjustment, choke cable adjustment, idle speed adjustment, fuel line inspection/replacement, fuel filter service, carburetor draining, and air filter service.
  • Engine Maintenance: Engine oil level check, oil and filter change, compression/leakdown test, valve clearance adjustment, engine mount inspection, engine fastener torque, CVT drying (90cc models), and exhaust spark arrestor cleaning.
  • Transmission and Final Drive: Transmission lubrication level check and change, drive chain inspection and adjustment, and sprocket inspection.
  • Electrical and Ignition System: Battery maintenance (removal, cleaning, installation, storage, voltage test, load test, charging procedure), fuse location, spark plug inspection, ignition timing, engine/frame ground check, tether switch test, ETC switch adjustment, key switch test, left hand switch assembly, daytime running lights test/replacement, tail light lamp replacement, indicator lamps replacement (90cc models), transmission switch testing/removal/installation, ignition system troubleshooting, RPM ignition limiter functions, ignition coil test, CDI output test, pulser coil output/resistance tests, charging system testing, voltage regulator/rectifier, stator/alternator tests, starter system troubleshooting, and starter motor service/disassembly/assembly.
  • Body/Suspension/Steering: Body removal procedures for Predator 50, Outlaw 90, and Sportsman 90, including footwell, cab, and bumper removal. Suspension component removal (shocks, control arms, swing arm). Steering component removal (steering post, tie rod). Handlebar exploded views. Decal replacement procedure.
  • Brakes: Front and rear brake service, including exploded views, shoe removal, backing plate removal, and brake lever adjustments.

Polaris PREDATOR 50 2009 Specifications

General IconGeneral
BrandPolaris
ModelPREDATOR 50 2009
CategoryOffroad Vehicle
LanguageEnglish

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