Polaris 2007 Predator 50 Outlaw 90 Sportsman 90 Service Manual – PDF

Description

Polaris 2007 Predator 50 Outlaw 90 Sportsman 90 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Polaris 2007 Predator 50 Outlaw 90 Sportsman 90 Service Manual – PDF DOWNLOAD

Language : English
Pages : 170
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Polaris 2007 Predator 50 Outlaw 90 Sportsman 90 Service Manual – PDF DOWNLOAD

GENERAL INFORMATION 1
MODEL INFORMATION 2
Model Identification 2
Engine Designation Numbers 2
VIN Identification 2
Engine Serial Number Location 2
Vehicle Identification Number Location 2
GENERAL SPECIFICATIONS 3
MODEL2007 PREDATOR 50 3
MODEL 2007 OUTLAW 90 3
MODEL 2007 SPORTSMAN 90 3
MODEL: 2007 PREDATOR 50 4
MODEL: 2007 OUTLAW / SPORTSMAN 90 5
MISCELLANEOUS INFORMATION 6
Publication Numbers 6
Paint Codes 6
Replacement Keys 6
Special Tools – Where Used 7
Standard Torque Specifications 8
Conversion Table 9
SAE Tap Drill Sizes 10
Metric Tap Drill Sizes 10
Decimal Equivalents 10
Glossary Of Terms 11
MAINTENANCE 13
PERIODIC MAINTENANCE CHART 15
Periodic Maintenance Overview 15
Maintenance Chart Key 15
Pre-Ride – 40 Hour Maintenance Interval 16
50 – 300 Hour Maintenance Interval 17
POLARIS LUBRICANTS AND SERVICE PRODUCTS 18
MAINTENANCE REFERENCES 19
GENERAL VEHICLE INSPECTION AND MAINTENANCE 20
Pre-Ride / Daily Inspection 20
Vehicle Component Inspection Locations 20
Frame, Nuts, Bolts and Fastener Inspection 21
Standard Torque Specifications 21
Kick-Start Lever and Operation 21
FUEL SYSTEM AND AIR INTAKE 22
Fuel System Safety 22
Speed Control System 22
Throttle Stop Speed Control System 22
Electronic Throttle Control (ETC) 22
ETC Operation 23
ETC Switch Adjustment 23
Choke Cable Adjustment 24
Idle Speed Adjustment 24
Fuel Lines 24
Pilot Air Screw Adjustment 25
Vent Lines 25
Fuel Filter 25
Fuel Valve Location 26
Carburetor Draining 26
Air Filter Service 27
Air Box Sediment Tube 27
ENGINE 28
Engine Oil Level 28
Engine Oil and Filter Change 28
Compression / Leakdown Test 29
Valve Clearance Adjustment 29
Engine Mounts 30
Engine Fastener Torque 30
CVT Drying (90cc Models) 30
Exhaust Spark Arrestor Cleaning 30
TRANSMISSION AND FINAL DRIVE 31
Transmission Lubrication 31
Transmission Lubricant Level 31
Transmission Lubricant Change 31
Drive Chain Inspection – 90cc Models 32
Drive Chain Inspection – 50cc Models 32
Drive Chain Adjustment – 50 and 90cc Models 32
Sprocket Inspection 33
ELECTRICAL AND IGNITION SYSTEM 33
Battery Maintenance Service Notes 33
Battery Removal – 50cc 34
Battery Removal – 90cc 34
Battery Cleaning 34
Battery Installation 35
Battery Storage 35
Fuses / Fuse Holder Location 35
Spark Plug Inspection 35
Ignition Timing 36
Engine / Frame Ground 36
STEERING AND SUSPENSION 36
Steering 36
Tie Rod End / Steering Inspection 37
Wheel Alignment 37
Toe Adjustment 38
Front Suspension Inspection 38
Rear Suspension Inspection 38
Suspension Spring Adjustment 39
BRAKE SYSTEM 39
Brake System Inspection 39
Brake Lever Travel 39
Brake Freeplay 40
Front Brake Adjustment 40
Rear Brake Adjustment 41
Brake Shoe Inspection 41
WHEELS AND TIRES 41
Wheels 41
Wheel, Hub and Spindle Torque Table 41
Wheel Inspection 41
Wheel Removal – Front / Rear 42
Wheel Installation – Front / Rear 42
Tire Pressure 42
Tire Inspection 42
ENGINE / TRANSMISSION 43
ENGINE SERVICE 45
Engine Exploded Views & Torque Values 45
Engine Exploded Views & Torque Values 46
Engine Exploded Views & Torque Values 47
Special Tools 48
Engine Service Data 48
Engine Service Data 49
Engine Service Data 50
Engine Service Data 51
Oil Flow Diagram 52
Piston / Ring Identification 53
Accessible Components 53
Engine Removal 53
Engine Installation Notes 54
Engine Lubrication 55
Transmission Lubrication 55
Engine Breather / Oil Separator 55
Finding Top Dead Center (TDC) 55
TOP-END DISASSEMBLY 56
Engine Disassembly 56
Cam Chain Tensioner Removal 56
Cam Chain Tensioner Inspection 56
Cylinder Head Removal 57
Rocker Arm Disassembly / Inspection 57
Camshaft Removal 58
Camshaft Inspection 58
Cylinder Head Inspection 59
Cylinder Head Surface Inspection 59
Combustion Chamber Inspection 59
Cylinder Head Disassembly 59
Valve Inspection 60
Valve Seat Reconditioning 61
Cylinder Head Assembly 63
Valve Sealing Test 64
Cylinder Removal 64
Cam Chain Tensioner Blade 64
Piston Removal 64
Cylinder Inspection 65
Cylinder Honing Procedure 65
Honing To Deglaze 65
Piston Inspection 66
Piston Ring Installed Gap 67
BOTTOM-END DISASSEMBLY 67
Flywheel Removal / Inspection 67
Stator Removal 67
Oil Pump Removal 68
Crankcase Disassembly 69
Crankshaft Removal 69
Crankshaft / Cam Chain / Sprocket Inspection 69
Crankcase Oil Strainer Inspection 70
ENGINE ASSEMBLY 70
Crankcase Assembly 70
Piston Ring Installation 70
Piston Installation 71
Tensioner Blade Installation 71
Cylinder Installation 71
Cylinder Head & Camshaft Installation 72
Cam Chain Tensioner Installation 73
TRANSMISSION 74
Transmission Disassembly and Inspection 74
Transmission Inspection 77
Transmission Assembly 79
Starter Drive Mechanism (Electric) 81
KICK START 83
Kick Start Disassembly / Inspection 83
Kick Start Assembly 84
TROUBLESHOOTING 86
Spark Plug Fouling 86
Engine (General) 86
FUEL SYSTEM 89
CARBURETION SYSTEM 90
Special Tools 90
Carburetor Function 90
Carburetion Specifications 91
CARBURETOR OPERATION 91
Operation Overview 91
Float System 92
Pilot Jet 92
Pilot Mixture Screw 92
Air / Fuel Mixture Ratio 93
Jet Needle 93
Needle Jet 93
Throttle Opening vs Fuel Flow 94
Throttle slide 94
Main Jet 94
Pilot System (Idle – 3/8 Throttle) 95
Slide Cutaway (1/8 – 3/8 Throttle) 95
Jet Needle / Needle Jet (3/8 – 3/4 Throttle) 96
Main System (3/4 to Full Throttle) 96
Fuel Delivery 97
Vent System 97
CARBURETOR SERVICE 97
Carburetor Float Bowl Draining 97
Carburetor Removal – General 98
Carburetor Disassembly – 50cc (Mikuni) 98
Carburetor Disassembly – 90cc (Keihin) 99
Carburetor Cleaning100
Carburetor Inspection101
Float Height Adjustment102
Carburetor Assembly102
Needle and Seat Leak Test102
FUEL TANK EXPLODED VIEW103
Fuel Tank Removal104
Fuel Valve Location104
Fuel Valve Service Predator 50 / Outlaw 90105
Fuel Valve Layout105
AIR CLEANER EXPLODED VIEW106
TROUBLESHOOTING107
Fuel Starvation / Lean Mixture107
Rich Mixture107
Poor Idle107
BODY / SUSPENSION / STEERING109
GENERAL INFORMATION110
Special Tools110
Torque Specifications110
BODY REMOVAL – PREDATOR 50110
Body Removal110
Footwell Removal111
Front Bumper Removal / Installation112
Predator 50 – Body Exploded View112
BODY REMOVAL – OUTLAW 90113
Rear Cab Removal113
Side Panel Removal113
Footwell Removal113
Front Cab Removal114
Front Bumper Removal / Installation114
Outlaw 90 – Body Exploded View115
BODY REMOVAL – SPORTSMAN 90116
Rear Cab Removal116
Side Panel Removal116
Footwell Removal 116
Front Cab Removal117
Bumper and Rack Removal118
Sportsman 90 – Body Exploded View118
Indicator Light / Ignition Switch Replacement119
SUSPENSION119
50cc Shocks and Springs119
90cc Shocks and Springs119
Front Shock Removal120
Rear Shock Removal120
FRONT CONTROL ARM – 50cc120
Control Arm Exploded View120
Control Arm Replacement121
FRONT A-ARM – 90cc122
A-arm Exploded View122
A-arm Replacement122
SWING ARM123
Removal123
STEERING – 50cc125
Steering Assembly Exploded View125
Steering Post Removal125
STEERING – 90cc126
Steering Assembly Exploded View126
Steering Post Removal126
TIE ROD127
Removal / Adjustment127
HANDLEBAR128
Predator 50 Exploded View128
Outlaw 90 Exploded View128
Sportsman 90 Exploded View128
DECAL REPLACEMENT128
BRAKES129
SPECIFICATIONS130
General Specifications130
Torque Specifications130
FRONT BRAKES131
Exploded View131
Front Brake Service131
REAR BRAKE135
Exploded View135
Rear Brake Service135
Brake Lever Adjustments137
CVT SYSTEM139
CVT SYSTEM140
CVT Maintenance / Inspection140
Drive Clutch Operation140
Driven Clutch Operation140
CVT System Drying141
CVT Overheating / Diagnosis141
Clutch Cover Removal142
Drive Belt Removal142
DRIVE CLUTCH SERVICE142
Drive Clutch Disassembly and Inspection142
Drive Clutch Assembly144
DRIVEN CLUTCH SERVICE145
Driven Clutch Disassembly and Inspection145
Driven Clutch Assembly147
ELECTRICAL149
GENERAL INFORMATION150
Special tools150
Electrical System Service Notes150
SWITCHES AND CONTROLS150
Brake Lever Switches150
Tether Switch Test151
Electronic Throttle Control (ETC)151
ETC Operation151
ETC Switch Adjustment152
Key Switch152
Left Hand Switch Assembly152
DAYTIME RUNNING LIGHTS153
“DRL” Test153
“DRL” Lamp Replacement153
TAIL LIGHT154
Tail Light Lamp Replacement154
INDICATOR LAMPS (90CC MODELS)154
Indicator Lamp Replacement154
TRANSMISSION SWITCH155
Transmission Switch – Circuit Breakout155
Testing155
Removal155
Installation156
IGNITION SYSTEM156
Overview156
Ignition System Troubleshooting156
Ignition System Testing157
RPM Ignition Limiter Functions158
RPM Limiter Specifications159
Ignition Coil Test159
CDI Output Test Using Peak Reading Adaptor159
Pulser Coil Output / Resistance Tests 159
CHARGING SYSTEM160
Charging System Testing160
Main Fuse / Fuse Holder Location161
Voltage Regulator / Rectifier161
Stator / Alternator Tests161
BATTERY162
Battery Maintenance Service Notes162
New Battery Activation162
Battery Removal – 50cc163
Battery Removal – 90cc163
Battery Cleaning164
Battery Installation164
Battery Voltage Test164
Battery Load Test164
Battery Charging Procedure164
Battery Storage165
STARTER SYSTEM165
Starter Relay165
Starter Motor Service165
Starter Disassembly165
Starter Brush Inspection / Replacement166
Armature Test166
Starter Reassembly167
Voltage Drop Test167
Starter System Troubleshooting167
Starter System Testing 168
Wiring Diagram169

DESCRIPTION:

Polaris 2007 Predator 50 Outlaw 90 Sportsman 90 Service Manual – PDF DOWNLOAD

GENERAL VEHICLE INSPECTION AND MAINTENANCE:

Pre-Ride / Daily Inspection Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.

G.B 05/04/25