Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF
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Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF DOWNLOAD
Description
Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF DOWNLOAD
FILE DETAILS:
Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF DOWNLOAD
Language : English
Pages : 103
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF DOWNLOAD
2004 Predator 50, Predator 90, Sportsman 90 0
INTRODUCTION 2
CHAPTER 1-GENERAL & MAINTENANCE 1
MODEL ID / SERIAL NUMBER LOCATION 2
2004 YOUTH MODELS 3
SPECIFICATIONS 4
PUBLICATION NUMBERS 7
PAINT CODES 7
INSPECTION SCHEDULE 7
STANDARD TORQUE SPECIFICATIONS 10
SPECIAL TOOLS 10
LUBRICANT AND MAINTENANCE PRODUCTS 10
2004 SPEED LIMITER SYSTEM OVERVIEW 11
VEHICLE INSPECTION / ADJUSTMENTS 12
TRANSMISSION LUBRICATION 15
THROTTLE OPERATION / IDLE – AIR SCREW ADJUST 16
THROTTLE CABLE / ETC ADJUSTMENTS 17
OIL PUMP ADJUSTMENTS / BLEEDING 18
OIL PUMP TROUBLESHOOTING 19
FUEL SYSTEM 19
COMPRESSION TEST 21
AIR FILTER SERVICE 21
SPARK PLUG 21
WHEELS AND TIRES 21
STEERING / ALIGNMENT 23
GLOSSARY OF TERMS 25
UNIT OF MEASURE CONVERSION TABLE 26
TAP DRILL CHARTS 27
DECIMAL EQUIVALENT CHART 27
CHAPTER 2-ENGINE & TRANSMISSION 29
CVT EXPLODED VIEW 30
SPECIAL TOOLS 30
TORQUE SPECIFICATIONS 30
ENGINE REMOVAL 31
ENGINE DISASSEMBLY 32
TRANSMISSION SERVICE 38
ENGINE COMPONENT INSPECTION 39
CYLINDER HONING 40
CRANKSHAFT RUNOUT INSPECTION 42
CONSTANT VARIABLE TRANSMISSION (CVT) SERVICE 43
ENGINE REASSEMBLY & INSTALLATION 46
KICK START AND SPRING INSTALLATION 51
STARTER DRIVE ONE WAY CLUTCH 52
ENGINE TROUBLESHOOTING 53
CHAPTER 3-FUEL / CARBURETION 55
CARBURETOR EXPLODED VIEW 56
CARBURETOR SPECIAL TOOLS 57
CARBURETOR SPECIFICATIONS 58
OPTIONAL MAIN JETS 58
HIGH ALTITUDE OPERATION 58
CARBURETOR OPERATION OVERVIEW 59
FUEL DELIVERY 64
VENT SYSTEM / FLOAT HEIGHT SETTING 64
NEEDLE AND SEAT LEAKAGE TEST 65
OIL CHECK VALVE PRESSURE TEST 65
CARBURETOR FLOAT BOWL DRAINING 65
TROUBLESHOOTING 66
CHAPTER 4-BODY AND STEERING 67
ENGINE MOUNTING EXPLODED VIEW 68
TORQUE SPECIFICATIONS / SPECIAL TOOLS 68
ENGINE MOUNTING 69
SHOCKS AND SPRINGS 69
SUSPENSION A-ARMS 70
STEERING 71
FRONT BRAKE 72
REAR BRAKE AND AXLE 73
FUEL AND OIL TANK 75
PREDATOR CAB 76
SPORTSMAN FRONT AND REAR CAB 77
SPORTSMAN HANDLEBAR ASSEMBLY 77
PREDAOTR HANDLEBAR ASSEMBLY 79
MUFFLER ASSEMBLY 81
CHAPTER 5-ELECTRICAL 83
SPECIAL TOOLS 84
ELECTRICAL SERVICE NOTES 84
2004 MODEL SPEED LIMITER SYSTEM 84
BRAKE LIGHT BULB REPLACEMENT 85
BATTERY SERVICE / TERMINALS AND BOLTS 85
BATTERY INSPECTION / REMOVAL 87
BATTERY INSTALLATION 87
OPEN CIRCUIT VOLTAGE TEST 87
LOAD TEST 88
OFF SEASON STORAGE 88
CHARGING PROCEDURE 89
CHARGING SYSTEM TESTING 90
CURRENT DRAW / KEY OFF TEST 91
CHARGING SYSTEM BREAK EVEN TEST 91
ALTERNATOR OUTPUT TEST 91
IGNITION SYSTEM / SPARK PLUG 92
STARTER SYSTEM TROUBLSHOOTING / VOLTAGE DROP TEST 92
STARTER SYSTEM DIGNOSIS 93
STARTER MOTOR DISASSEMBLY 94
BRUSH INSPECTION / REPLACEMENT 94
ARMATURE TESTING 95
STARTER ASSEMBLY 95
ELECTRONIC THROTTLE CONTROL (ETC) 96
COIL TESTS 97
IGNITION SYSTEM TROUBLESHOOTING 97
WIRING DIAGRAM – 50 CC MODELS 98
WIRING DIAGRAM – 90 CC MODELS 99
INDEX100
A-D100
E-M101
N-T102
V-Y103
DESCRIPTION:
Polaris 2004 Sportsman 90 Predator 50 90 Service Manual – PDF DOWNLOAD
GENERAL INFORMATION:
SPEED CONTROL SYSTEMS:
- Electronic Speed Control System This Polaris ATV is equipped with an electronic speed control system, which controls the engine RPM and speed of the ATV.
- Top speed can be adjusted by removing or installing the jumper on the CDI (A). With the jumper installed, 50cc models will travel no faster than 10 mph and 90cc models will travel no faster than 15 mph.
- With the jumper removed, 50cc models will travel no faster than 15mph and 90ccmodels will travel no faster than 30 mph. Jumper Removal and Installation
DRIVE CHAIN INSPECTION:
DRIVE CHAIN INSPECTION AND ADJUSTMENT:
G.B 05/04/25
