2013-2018 Outlaw 50 / 2013-2016 Outlaw 90

Service Manual
FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service 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 the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.

Publication Printed October 2017 (PN 9928505 R01)

© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements 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.
SAFETY WARNINGS
Throughout this manual, important information is brought to your attention by the following symbols:

WARNING

SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.

CAUTION

SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.

CAUTION

CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.

NOTE

NOTE provides key information by clarifying instructions.

IMPORTANT

IMPORTANT provides key reminders during disassembly, assembly and inspection of components.

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.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX

REV DATE CHANGES

R01 10/03/2017 Initial release
2013-2018 Outlaw 50 / 2013-2016 Outlaw 90
Service Manual
Chapter Summary

CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / TRANSMISSION
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: BODY / STEERING / SUSPENSION
CHAPTER 6: BRAKES
CHAPTER 7: CVT
CHAPTER 8: ELECTRICAL
 GENERAL INFORMATION

CHAPTER 1 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
ENGINE NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE IDENTIFICATION NUMBER AND ENGINE SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL OVERVIEW: OUTLAW 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: OUTLAW 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL OVERVIEW: OUTLAW 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL OVERVIEW: SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: OUTLAW 90 / SPORTSMAN 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11

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GENERAL INFORMATION

VEHICLE IDENTIFICATION
MODEL NUMBER DESIGNATION
Example: A14KA09AD

MODEL DRIVE- ENGINE /

GROUP CHASSIS CATEGORY OPTION REGION
YEAR LINE MOTOR CODE
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th** 10th
A 1 4 K A 0 9 A D
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.

MODEL NUMBER DESIGNATION (2015 +)

Example: R15RUE57AC

GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5 R U E 5 7 A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

Example: 4XARUE573FG000000

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

ENGINE MODIFIER

MFG. LOCATION
MODEL YEAR *
CHECK DIGIT
ENGINE SIZE
DRIVELINE

MODIFIER
CHASSIS

CHASSIS

WORLD MFG. ID
INDIVIDUAL SERIAL NO.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A R U E 5 7 3 F G 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018

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 GENERAL INFORMATION

ENGINE NUMBER DESIGNATION

50cc Model: M10A - Single Cylinder, Air Cooled, SOHC, 4-Stroke, Electric Start 1
90cc Model: H18S - Single Cylinder, Air Cooled, SOHC, 4-Stroke, Electric Start

VEHICLE IDENTIFICATION NUMBER AND ENGINE SERIAL NUMBER LOCATION

The Vehicle Identification Number (VIN) and engine serial number are important for identification purposes. Whenever
corresponding about a Polaris utility vehicle, be sure to refer to the VIN and the engine serial number.
The engine serial number can be found stamped on the top LH side of the crankcase as shown below. See the
illustrations below for engine serial number and VIN locations.

OUTLAW 50 SPORTSMAN 90 / OUTLAW 90

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GENERAL INFORMATION

GENERAL SPECIFICATIONS
MODEL OVERVIEW: OUTLAW 50
MODEL NUMBER: A13KA09AF, AD / A14KA09AF, AD / A15YAK05AF, AD / A16YAK05AF, AD / AD17YAK05AF, AD
CATEGORY DIMENSION
Length 48 in. / 122 cm
Width 31.5 in. / 80 cm
Height 28 in. / 71 cm
Wheel Base 33 in. / 84 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 90 lbs. / 41 kg
Dry Weight 215 lbs. / 98 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 1.2 gal / 4.5L

MODEL: OUTLAW 50
MODEL #: A13KA09AF, AD / A14KA09AF, AD / A15YAK05AF, AD / A16YAK05AF, AD / A17YAK05AF , AD

ENGINE CARBURETION
Platform Aeon SOHC 4-Stroke Fuel Capacity 1.2 gal. (4.5 L)
Engine Displacement 49.5cc Fuel Reserve Capacity 0.22 gal. (0.85 L)
Number of Cylinders 1 89 Oxygenated /
87 Non-Oxygenated
Bore & Stroke (mm) 39 x 41.4 mm (Non-Ethanol)
Compression Ratio 9.2:1 Fuel Recommendation
Add Polaris Carbon Clean Fuel
Compression Pressure 115-155 psi Treatment At Each Fill
(1/2 oz. per Gallon)
Engine Idle Speed 1500 ± 100 RPM
Engine Max Speed 7500 RPM WHEELS / BRAKES
Cooling System Air Cooled Tire Size / Bolt Pattern -
16 x 6.5 - 7 / 4-110
Front
Overheat Warning n/a
Tire Size / Bolt Pattern - Rear 16 x 8 - 7 / 4-110
Lubrication Oil Pump Pressurized Wet Sump
Air Pressure - F/R Tires 2 psi (13.8 KPa)
Polaris Performance (PS-4)
Oil Requirements Synthetic Extreme Duty Brakes - Front / Rear Drum
30 oz. (900 ml) Parking Brake Mechanical Lock
Exhaust System USFS Approved
DRIVETRAIN
CARBURETION Transmission Type Forward Gear Only
Carburetor Model Mikuni VM12H 11.8 oz. (350 ml) or to bottom of
Transmission Lubricant Capacity
Main Jet 62 fill hole threads

Pilot Jet 12.5 Drive Type Chain

Jet Needle 3X6-4 Clutch Type Automatic CVT
Needle Jet n/a Drive Belt 0453455
Throttle Valve Cutaway n/a
Inlet Valve Seat Size 1.2 STEERING / SUSPENSION
2.5 Turns Out Single Control Arm /
Front Suspension Style
Pilot / Air Screw (Initial setting, varies by ATV) Non-Adjust Shocks

Float Height Front Travel 3 in. / 7.6 cm

Parallel To Float Bowl
Mono Shock Swingarm /
Fuel Delivery Gravity Feed System Rear Suspension Style
Cam Adjust Shock

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 GENERAL INFORMATION

STEERING / SUSPENSION ELECTRICAL

Rear Travel 3 in. / 7.6 cm Fuses (1) 7 Amp 1
Ground Clearance 4 in. / 10 cm Starting Electric / Kick Start Backup
Shock Preload Adjustment Rear - Cam Adjust
Toe Out 1/8 in. - 1/4 in / 3 - 6 mm
JETTING CHART
Altitude Ambient Temperature
ELECTRICAL Meters
Below 20°F Above +15°F
(Feet)
Alternator Output 56 Watts @ 1700 RPM Below -7°C Above -10°C
Main Jet = 65 Main Jet = 62.5
Voltage Regulator Single Phase / Full Wave 454955 453963
0-2400
Daytime Running Lights 15 Watts (0-8000) Pilot Jet = 15 Pilot Jet = 12.5
454956 453965
Brake Light 21 watts Position = 4 Position = 4

Tail Light 5 watts Main Jet = 62.5 Main Jet = 60

2400+ 453963 454954
Ignition System CDI Ignition (8000+) Pilot Jet = 15 Pilot Jet = 12.5
454956 453965
Ignition Timing 17.5° BTDC @ 1700 RPM Position = 4 Position = 4

Spark plug / Gap NGK CR6HSA

.024 - .028 in./ .6-.7 mm
Battery / Model / Amp Hr Low Maintenance / 12V / 5 AH MODEL OVERVIEW: OUTLAW 90
MODEL NUMBER: A13KA09AF, AD / A14KA09AF, AD / A16YAK09AF
CATEGORY DIMENSION
Length 61.25 in. / 156 cm
Width 36.75 in. / 93 cm
Height 38.5 in. / 98 cm
Wheel Base 41.5 in. / 105 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 180 lbs. / 81.6 kg
Dry Weight 283 lbs. / 128 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 1.7 gal. / 6.4 L

MODEL OVERVIEW: SPORTSMAN 90

MODEL NUMBER: A13FA09AA / A14FA09AA / A16YAF09AA
CATEGORY DIMENSION
Length 61.75 in. / 157 cm
Width 36.75 in. / 93 cm
Height 38.5 in. / 98 cm
Wheel Base 41.5 in. / 105 cm
Ground Clearance 4 in. / 10 cm at Swing Arm
Rider Capacity / Max. Weight 1 rider / 180 lbs. / 81.6 kg
Dry Weight 305 lbs. / 138 kg
Oil Capacity 30 oz. / 900 ml
Fuel Capacity 2 gal. / 7.7 L
Front Rack Capacity 15 lbs. / 6.8 kg
Rear Rack Capacity 30 lbs. / 13.6 kg

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GENERAL INFORMATION

MODEL: OUTLAW 90 / SPORTSMAN 90

OUTLAW MODEL #: A13KA09AF, AD / A14KA09AF, AD / A16YAK09AF
SPORTSMAN MODEL #: A13FA09AA / A14FA09AA / A16YAF09AA

ENGINE DRIVETRAIN
Platform Aeon SOHC 4-Stroke Transmission Type Integrated F/N/R
Engine Displacement 89.9cc 11.8 oz. (350 ml) or to bottom of
Transmission Lubricant Capacity
fill hole threads
Number of Cylinders 1
Drive Type Chain
Bore & Stroke (mm) 47 x 51.8 mm
Clutch Type Automatic CVT
Compression Ratio 9.2:1
Drive Belt 0453455
Compression Pressure 115-155 psi
Engine Idle Speed 1700 ± 100 Rpm STEERING / SUSPENSION
Engine Max Speed 8500 RPM Front Suspension
Single A-arm / Cam Adjust Shocks
Style
Cooling System Air Cooled
Front Travel 5 in. / 12.7 cm
Lubrication Oil Pump Pressurized Wet Sump
Rear Suspension Style Mono Shock Swingarm / Cam Adjust Shock
Polaris Performance (PS-4)
Oil Requirements Synthetic Extreme Duty Rear Travel 6 in. / 15.2 cm
30 oz. (900 ml)
Ground Clearance 4 in. / 10 cm
Exhaust System USFS Approved Shock Preload Front - Cam Adjust
Adjustment Rear - Cam Adjust
CARBURETION Toe Out 1/8 in. - 1/4 in / 3 - 6 mm
Carburetor model Keihin / Sunworld PTE16
Main Jet 80 ELECTRICAL
Pilot Jet 40 Alternator Output 56 Watts @ 1700 RPM
Jet Needle 89Q - 3 clip Voltage Regulator Single Phase / Full Wave
Needle Jet 11 Daytime Running Lights 15 Watts
Throttle Valve Brake Light 21 watts
Cutaway 3.0 SA
Tail Light 5 watts
1.75 ± .5 Turns Out
Pilot / Air Screw (Initial setting, varies by ATV) Ignition System CDI Ignition
Float Height Parallel To Float Bowl Ignition Timing 17.5° BTDC @ 1700 RPM
Fuel Delivery Gravity Feed System Spark plug / Gap NGK CR6HSA
.024 - .028 in./ .6-.7 mm
1.7 gal. (6.4 L) - 2 gal. (7.7 L) -
Fuel Capacity Battery / Model / Amp Hr Low Maintenance / 12V / 5 AH
Outlaw 90 Sportsman 90
Fuel Reserve 0.23 gal. (0.86 L) - 0.22 gal. (0.85 L) - Fuses (1) 7 Amp
Capacity Outlaw 90 Sportsman 90
Starting Electric / Kick Start Backup
89 Oxygenated / 87 Non-Oxygenated (Non-
Ethanol) Indicator Panel Neutral / Reverse
Fuel
Recommendation Add Polaris Carbon Clean Fuel JETTING CHART
Treatment At Each Fill
(1/2 oz. per Gallon) Altitude Ambient Temperature
Meters Below 20°F Above +15°F
(Feet) Below -7°C Above -10°C
WHEELS / BRAKES Main Jet = 82 Main Jet = 80
Tire Size / Bolt Pattern - 0-2400 454196 454888
19 x 7 - 8 / 4-110 Pilot Jet = 42 Pilot Jet = 40
Front (0-8000)
454958 454887
Tire Size / Bolt Pattern - Rear 18 x 9.5 - 8 / 4-110 Position = 4 Position = 4
Air Pressure - F/R Tires 3 psi (20.7 KPa) Main Jet = 80 Main Jet = 78
2400+ 454888 454957
Brakes - Front / Rear Drum Pilot Jet = 42 Pilot Jet = 40
(8000+)
Parking Brake Mechanical Lock 454958 454887
Position = 4 Position = 4

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 GENERAL INFORMATION

GENERAL INFORMATION
PUBLICATION NUMBERS 1
YEAR MODEL MODEL NO. OWNER’S MANUAL PN PARTS MANUAL PN
Outlaw 50 A13KA05AF, AD 9923971 9923972
2013 Outlaw 90 A13KA09AF, AD 9923967 9923974
Sportsman 90 A13FA09AA 9923967 9923968
Outlaw 50 A14KA05AF, AD 9924633 9924634
2014 Outlaw 90 A14KA09AF, AD 9924620 9924631
Sportsman 90 A14FA09AA 9924620 9924621
Outlaw 50 A15YAK05AF, AD 9925742 9925746
2015 Outlaw 90 NA NA NA
Sportsman 90 NA NA NA
Outlaw 50 A16YAK05AF, AD 9926607 9926606
2016 Outlaw 90 A16YAK09AF 9926672 9926671
Sportsman 90 A16YAF09AA 9926672 9926670
2017 Outlaw 50 A17YAK05A4, A6 9927397 9927401

NOTE
When ordering service parts be sure to use the correct parts manual.

NOTE
Polaris factory publications can be found at www.polarisindustries.com or purchased from www.purepolaris.com.

PAINT CODES
PAINTED PART COLOR DESCRIPTION POLARIS NUMBER
Frame / Swing Arm Medium Gloss Black P-067
Frame / Swing Arm Cloud Silver P-385

REPLACEMENT KEYS
Replacement keys can be made from the original key. Polaris offers replacement key blanks (0453013) that can be cut
to match the original. Should both keys become lost, ignition switch replacement is required.

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GENERAL INFORMATION

SPECIAL TOOLS
Special Tools may be required to service this ATV. Some of the tools listed are mandatory, while other tools may be
substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any
Polaris product.

2870390 PA-45153 PA-48701

Piston Support Block Flywheel Puller Adaptor, Valve Spring Compressor

PA-46502 2870872 2870623

Valve Spring Compressor Shock Spanner Wrench Shock Absorber Spring
Compression Tool

2870836 PV-43568 PV-39991

Battery Hydrometer Fluke™ 73 Digital Multimeter Peak Reading Adaptor

2870975 PV-63070 2870630

Mity Vac™ Pressure Test Tool Christie Multi-Battery Charger Timing Light

PA-47361 PV-26900-8 PV-35667-A

Carburetor Adjustment Screwdriver 26 Blade Thickness Gauge (Feeler Cylinder Leakdown Tester
Gauge)

PV-39951-A
Tachometer

Bosch Automotive Service Solutions: 1-800-328-6657 or http://polaris.service-solutions.com/

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 GENERAL INFORMATION

CONVERSION TABLE
UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
1
ft-lbs x 12 = in-lbs
in-lbs x 0.0833 = ft-lbs
ft-lbs x 1.356 = Nm
in-lbs x 0.0115 = kg-m
Nm x 0.7376 = ft-lbs
kg-m x 7.233 = ft-lbs
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm
inch x 25.4 = mm
mm x 0.03937 = inch
inch x 2.54 = cm
mile (mi) x 1.6 = km
km x 0.6214 = mile
ounces (oz) x 28.35 = grams (g)
fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)
cubic centimeters (cc) x .03381 = fluid ounces
grams (g) x 0.035 = ounces

pounds (lb) x 0.454 = kg

kilogram (kg) x 2.2046 = lbs
cubic inches (cu in) x 16.387 = cc

cubic centimeters (cc) x 0.061 = cubic inches

US quarts x 0.946 = liters (L)
liters (L) x 1.057 = US quarts
US gallons x 3.785 = liters (L)
liters (L) x 0.264 = US gallons
PSI x 6.895 = kilopascals (kPa)
kilopascals (kPa) x 0.145 PSI
π (3.14) x Radius² x Height = = cylinder volume
°C to °F: 9/5 (°C + 32) = °F
°F to °C: 5/9 (°F − 32) = °C

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GENERAL INFORMATION

SAE TAP / DRILL SIZES METRIC TAP / DRILL SIZES

THREAD THREAD NEAREST
SIZE DRILL SIZE SIZE DRILL SIZE TAP SIZE DRILL SIZE DECIMAL FRACTION
#0–80 3/64 1/2–13 27/64 3 x .50 #39 0.0995 3/32
#1–64 53 1/2–20 29/64 3 x .60 3/32 0.0937 3/32
#1–72 53 9/16–12 31/64 4 x .70 #30 0.1285 1/8
#2–56 51 9/16–18 33/64 4 x .75 1/8 0.125 1/8
#2–64 50 5/8–11 17/32 5 x .80 #19 0.166 11/64
#3–48 5/64 5/8–18 37/64 5 x .90 #20 0.161 5/32
#3–56 45 3/4–10 21/32 6 x 1.00 #9 0.196 13/64
#4–40 43 3/4–16 11/16 7 x 1.00 16/64 0.234 15/64
#4–48 42 7/8–9 49/64 8 x 1.00 J 0.277 9/32
#5–40 38 7/8–14 13/16 8 x 1.25 17/64 0.265 17/64
#5–44 37 1–8 7/8 9 x 1.00 5/16 0.3125 5/16
#6–32 36 1–12 59/64 9 x 1.25 5/16 0.3125 5/16
#6–40 33 1 1/8–7 63/64 10 x 1.25 11/32 0.3437 11/32
#8–32 29 1 1/8–12 1 3/64 10 x 1.50 R 0.339 11/32
#8–36 29 1 1/4–7 1 7/64 11 x 1.50 3/8 0.375 3/8
#10–24 24 1 1/4–12 1 11/64 12 x 1.50 13/32 0.406 13/32
#10–32 21 1 1/2–6 1 11/32 12 x 1.75 13/32 0.406 13/32
#12–24 17 1 1/2–12 1 27/64
#12–28 4.6 mm 1 3/4–5 1 9/16
1/4–20 7 1 3/4–12 1 43/64
1/4–28 3 2–4 1/2 1 25/32
5/16–18 F 2–12 1 59/64
5/16–24 I 2 1/4–4 1/2 2 1/32
3/8–16 O 2 1/2–4 2 1/4
3/8–24 Q 2 3/4–4 2 1/2
7/16–14 U 3–4 2 3/4
7/16–20 25/64

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 GENERAL INFORMATION

DECIMAL EQUIVALENTS
FRACTION DECIMAL MM TO INCHES FRACTION DECIMAL MM TO INCHES 1
1/64 0.0156″ 41/64 0.6406″
1/32 0.0312″ 1 mm = 0.0394″ 21/32 0.6563″ 17 mm = 0.6693″
3/64 0.0469″ 43/64 0.6719″
1/16 0.0625″ 11/16 0.6875″
5/64 0.0781″ 2 mm = 0.0787″ 45/64 0.7031″ 18 mm = 0.7087″
3/32 0.0938″ 23/32 0.7188″
7/64 0.1094″ 3 mm = 0.1181″ 47/64 0.7344″ 19 mm = 0.7480″
1/8 0.1250″ 3/4 0.750″
9/64 0.1406″ 49/64 0.7656″
5/32 0.1563″ 4 mm = 0.1575″ 25/32 0.7813″ 20 mm = 0.7874″
11/64 0.1719″ 51/64 0.7969″
3/16 0.1875″ 5 mm = 0.1969″ 13/16 0.8125″ 21 mm = 0.8268″
13/64 0.2031″ 53/64 0.8281″
7/32 0.2188″ 27/32 0.8438″
15/64 0.2344″ 6 mm = 0.2362″ 55/64 0.8594″ 22 mm = 0.8661″
1/4 0.25″ 7/8 0.875″
17/64 0.2656″ 7 mm = 0.2756″ 57/64 0.8906″ 23 mm = 0.9055″
9/32 0.2813″ 29/32 0.9063″
19/64 0.2969″ 59/64 0.9219″
5/16 0.3125″ 8 mm = 0.3150″ 15/16 0.9375″ 24 mm = 0.9449″
21/64 0.3281″ 61/64 0.9531″
11/32 0.3438″ 9 mm = 0.3543″ 31/32 0.9688″ 25 mm = 0.9843″
23/64 0.3594″ 63/64 0.9844″
3/8 0.375″ 1 1.000″
25/64 0.3906″ 10 mm = 0.3937″
13/32 0.4063″
27/64 0.4219″ 11 mm = 0.4331″
7/16 0.4375″
29/64 0.4531″
15/32 0.4688″ 12 mm = 0.4724″
31/64 0.4844″
1/2 0.500″ 13 mm = 0.5118″
33/64 0.5156″
17/32 0.5313″
35/64 0.5469″ 14 mm = 0.5512″
9/16 0.5625″
37/64 0.5781″ 15 mm = 0.5906″
19/32 0.5938″
39/64 0.6094″
5/8 0.625″ 16 mm = 0.6299″

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GENERAL INFORMATION

NOTES

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 MAINTENANCE

CHAPTER 2
MAINTENANCE
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3 2
PERIODIC MAINTENANCE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
PRE-RIDE - 10 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
20 - 300 HOUR MAINTENANCE INTERVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
POLARIS LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
LUBRICANTS AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
MAINTENANCE REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GENERAL VEHICLE INSPECTION AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
VEHICLE COMPONENT INSPECTION LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
FRAME, NUTS, BOLTS AND FASTENER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
STANDARD TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
KICK-START LEVER AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
FUEL SYSTEM SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
THROTTLE STOP SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
THROTTLE RELEASE SWITCH (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
TRS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
TRS SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
CHOKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.13
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
PILOT AIR SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
FUEL FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
FUEL VALVE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
CARBURETOR DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
AIR BOX SEDIMENT TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
ENGINE OIL AND FILTER CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
COMPRESSION / LEAKDOWN TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
CVT DRYING (90CC MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
EXHAUST SPARK ARRESTOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
TRANSMISSION AND FINAL DRIVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

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MAINTENANCE

TRANSMISSION LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.23

TRANSMISSION LUBRICANT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
DRIVE CHAIN INSPECTION - 90CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
DRIVE CHAIN INSPECTION - 50CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
DRIVE CHAIN ADJUSTMENT - 50 AND 90CC MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BATTERY MAINTENANCE SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BATTERY REMOVAL - 50CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26
BATTERY REMOVAL - 90CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
BATTERY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
FUSES / FUSE HOLDER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
SPARK PLUG INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
ENGINE / FRAME GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
STEERING AND SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
TIE ROD END / STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.31
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
FRONT SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
REAR SUSPENSION INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
SUSPENSION SPRING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
BRAKE SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
BRAKE LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
BRAKE FREEPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
FRONT BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.35
REAR BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
BRAKE SHOE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
WHEEL, HUB AND SPINDLE TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
WHEEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
WHEEL REMOVAL - FRONT / REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
WHEEL INSTALLATION - FRONT / REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39

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PERIODIC MAINTENANCE CHART

PERIODIC MAINTENANCE OVERVIEW
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment
and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement
parts, use genuine Polaris parts available from your Polaris dealer. 2
NOTE
Service and adjustments are critical. If you’re not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the
oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to
rise, discontinue use and determine the cause or see your dealer.

MAINTENANCE CHART KEY

The following symbols denote potential items to be aware of during maintenance:
■ = CAUTION: Due to the nature of these adjustments, it is recommended this service be performed by an authorized
Polaris dealer.
▶ = SEVERE USE ITEM – See Above
E = Emission Control System Service (California).

NOTE
Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.

WARNING
Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these services.

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PRE-RIDE - 10 HOUR MAINTENANCE INTERVAL

MAINTENANCE INTERVAL
ITEM (WHICHEVER COMES FIRST) REMARKS
HOURS CALENDAR MILES (KM)
■ Steering - Pre-Ride - Check for free operation
▶ Front-Suspension - Pre-Ride -
▶ Rear-Suspension - Pre-Ride - Make adjustments as needed

Tires - Pre-Ride -
Engine Stop Switch - Pre-Ride - Check operation
▶ Brake Lever Travel - Pre-Ride - Make adjustments as needed
Brake System - Pre-Ride - Check operation
Daytime Running Lights - Pre-Ride - Check for proper operation
Check condition and slack;
Drive Chain - Pre-Ride - refer to “Drive Train Adjustment”
Brake Light - Pre-Ride - Check for proper operation

Throttle - Pre-Ride - Check operation

Wheels / Fasteners - Pre-Ride -
Make adjustments as needed
Frame Fasteners - Pre-Ride -
▶E Engine Oil Level - Pre-Ride - Make adjustments as needed

▶E Air Filter, Pre-Filter - Daily - Inspect; clean often, replace as needed

▶ Air Box Sediment Tube - Daily - Drain deposits when visible
Check operation; apply dielectric grease if
Head Lamp / Tail Lamp - Daily - replacing
Drain water as needed, check often
CVT Housing - Weekly - if operating in wet conditions
Brake Lever Travel /
▶■ 10 H Monthly 100 (160) Inspect regularly
Brake Freeplay
Clean; check condition; adjust gap;
■E Spark Plug 10 H Monthly 100 (160)
replace as needed
Idle Speed 10 H Monthly 100 (160) Check; adjust as needed

■E Choke 10 H Monthly 100 (160) Check for proper operation

Engine Oil Change Perform a break-in oil change after
10 H 1M 100 (160)
(Break-In Period) the first 10 hours of operation
Transmission Oil Perform a break-in oil change after
▶ 10 H 1M 100 (160)
(Break-In Period) the first 10 hours of operation
Drive Chain Adjust and lubricate after
▶ 10 H 1M 100 (160)
(Break-In Period) the first 10 hours of operation
Valve Clearance Check clearance after the first 10 hours of
■E 10 H 1M 100 (160)
(Break-In Period) operation; adjust to specification if required
▶ Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
■ Have an authorized Polaris dealer perform these services.

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20 - 300 HOUR MAINTENANCE INTERVAL

MAINTENANCE INTERVAL
ITEM (WHICHEVER COMES FIRST) REMARKS
HOURS CALENDAR MILES (KM)
Battery 20 H Monthly 200 (320) Check terminals; clean; test 2
Drain and change the oil; perform a break-in oil
▶ Engine Oil Change 30 H 6M 300 (480)
change after the first 10 hours of operation
Drain and change the oil; perform a break-in oil
▶ Transmission Oil 40 H 12 M 400 (640)
change after the first 10 hours of operation
Clean filter at every oil change; clean annually if
▶ Oil Pre-Filter Screen 40 H 12 M 400 (640)
ATV is operated less than 10 hours
▶ General Lubrication 50 H 3M 500 (800) Lubricate all grease fittings, pivots, & cables
Check clearance; adjust to specification if required;
perform break-in adjustment after the first 10
■E Valve Clearance 50 H 3M 500 (800)
hours
of operation

Carburetor Float Bowl 50 H 6M 500 (800) Drain bowl periodically and prior to storage
Throttle Cable / 500 (800) Inspect; adjust; lubricate; replace if necessary
■E 50 H 6M
TRS Switch
■E Choke Cable 50 H 6M 500 (800) Inspect; adjust; lubricate; replace if necessary
Carburetor Intake
E 50 H 6M 500 (800) Inspect for proper sealing / air leaks
Flange

▶■ Brake Shoe Wear 50 H 6M 500 (800) Inspect; replace as needed

■ Drive Belt 50 H 6M 500 (800) Inspect; replace as needed

Check for leaks at tank cap, lines, fuel valve, filter
■E Fuel System 100 H 12 M 1000 (1600)
carburetor, replace lines every two years

■E Fuel Filter 100 H 12 M 1000 (1600) Replace yearly

▶ Engine Mounts 100 H 12 M 1000 (1600) Inspect

Inspect secondary air system filter and exhaust -
Exhaust Muffler / Pipe 100 H 12 M 1000 (1600)
clean as required

■E Ignition Timing 100 H 12 M 1000 (1600) Inspect

Inspect for wear, routing, security; apply dielectric
▶ Wiring 100 H 12 M 1000 (1600)
grease to connectors subjected to water, mud, etc
Clutches
■ 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
(Drive and Driven)

■ Front Wheel Bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

Spark Arrestor 300 H 36 M 3000 (4800) Clean out
■ Toe Adjustment - - - Inspect periodically; adjust when parts are needed
▶ Perform these procedures more often for vehicles subjected to severe use.
E Emission Control System Service (California)
■ Have an authorized Polaris dealer perform these services.

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POLARIS LUBRICANTS AND SERVICE PRODUCTS

LUBRICANTS AND SERVICE PRODUCTS
PART NO. DESCRIPTION
Engine Lubricant
Polaris Performance Synthetic (PS-4)
2878920 Extreme Duty Oil (Quart)
Polaris Performance Synthetic (PS-4)
2878922 Extreme Duty Oil (2 Quart)
Polaris Performance Synthetic (PS-4)
2878919 Extreme Duty Oil (Gallon)

2870791 Fogging Oil (12 oz. Aerosol)

Transmission Lubricant
Polaris AGL (ATV Gearcase Lubricant)
2878068 (qt.)
Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season (3 oz.)

Premium All Season Grease
2871322 (3 oz. cartridge) (24 Count)
Premium All Season Grease
2871423 (14 oz. cartridge) (10 Count)

2871460 Starter Drive Grease (2 oz.) (12 Count)

2871329 Dielectric Grease (Nyogel™)

2872348 Chain Lube, Aerosol (16 oz.) (12 Count)

Additives / Seals / Thread Locking Agents / Misc.

2871950 Loctite® 242™ (6 ml.) (12 Count)

2871557 Crankcase Sealant, 3-Bond 1215 (5oz.)

2871326 Premium Carbon Clean (12 oz.) (12 Count)

2870652 Fuel Stabilizer (16 oz.) (12 Count)

NOTE
The number count supplied in the table indicates the number of units that are shipped with each order.

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MAINTENANCE REFERENCES

# ITEM LUBRICATION METHOD FREQUENCY*

1 Engine Oil Polaris Performance Check level or Check during pre-ride inspection and change
Synthetic (PS-4) change oil oil every 30 hours or 6 months.
Extreme Duty Oil
2 Transmission Polaris ATV Gearcase Check level or Inspect periodically and change lubrication
Lubricant (AGL) change lube every 40 hours or annually.
3 Drive Chain Polaris Chain Lube Lubricate drive Lubricate as required and before each ride in
or SAE 80/90 chain wet conditions. More often in severe use.
4 Front Polaris Premium All Inspect; tighten
Suspension Season Grease** fasteners; Every 3 months or 50 hours (also after
(A-Arm and grease zerks washing ATV or driving in water). More often in
Spindle) severe use.

* More often under severe use, such as operated in water or under severe loads.
**Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special.

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GENERAL VEHICLE INSPECTION AND MAINTENANCE

PRE-RIDE / DAILY INSPECTION
Perform the pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance. See Pre-Ride -
10 Hour Maintenance Interval, page for maintenance schedule.

VEHICLE COMPONENT INSPECTION

LOCATIONS

Outlaw 50

Sportsman 90

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FRAME, NUTS, BOLTS AND FASTENER KICK-START LEVER AND OPERATION

INSPECTION If the battery becomes too weak to start the engine, use
Periodically inspect the torque of all fasteners in the kick-start lever to start the engine until the battery is
accordance with the maintenance schedule. Check that serviced.
all cotter pins are in place. Refer to specific fastener
torques listed in each chapter.
2
STANDARD TORQUE SPECIFICATIONS
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 when available
for torque values of fasteners before using standard
torque.

Standard Fastener Torques

TORQUE
FASTENER TORQUE
(FT-LBS / IN-
THREAD SIZE (NM)
LBS)

5 mm bolts
44 in-lbs 5 Nm
and nuts
6 mm bolts 1. Position the vehicle on a level surface.
89 in-lbs 10 Nm
and nuts 2. Shift the transmission into neutral (if equipped).
8 mm bolts 3. Lock the parking brake.
16 ft-lbs 22 Nm
and nuts 4. Push the engine stop switch up to the RUN position.
10 mm bolts 5. Turn the key ON.
26 ft-lbs 35 Nm
and nuts
6. Fold out the kick start lever and place your foot on
12 mm bolts the lever. Thrust your heel downward to crank the
41 ft-lbs 55 Nm
and nuts engine.
4 mm screws 27 in-lbs 3 Nm
5 mm screws 35 in-lbs 4 Nm
6 mm
106 in-lbs 12 Nm
Hex bolts
8 mm
20 ft-lbs 27 Nm
Hex bolts
10 mm
30 ft-lbs 40 Nm
Hex bolts

7. After the engine has started, fold the kick-start lever

into place.

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FUEL SYSTEM AND AIR INTAKE

FUEL SYSTEM SAFETY 1. Remove the seat to access the jumper terminal.
2. Remove the two screws from the jumper terminal q
WARNING to remove or install the jumper wire.
• Gasoline is highly flammable and explosive under
certain conditions.
• Always exercise extreme caution whenever handling
gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or
near the area where refueling is performed or where
gasoline is stored.
• If gasoline spills on your skin or clothing, immediately
wash it off with soap and water and change clothing.
• Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause
loss of consciousness or death in a short time.
• EFI components are under high pressure. Verify 3. Reinstall the screws
system pressure has been relieved before disassembly.
4. Install the seat.
• Never drain the fuel system when the engine is hot.
Severe burns may result.

SPEED CONTROL SYSTEM

ELECTRONIC SPEED CONTROL SYSTEM
Adjust speed by removing or installing the jumper wire on
the terminals located under the seat.
Per ANSI / SVIA-1-2010 (sec. 6.2) AS DELIVERED TO
THE CONSUMER, the speed of youth models is
restricted to 10 MPH or less for the 50cc Y-6 + models
and 15 MPH or less for the 90cc Y-10+ models.
The dealer CANNOT, under any circumstances, either
prior to the sale or later, even at the consumer's request,
remove or adjust any speed limiting devices.
Youth model Polaris ATVs have an adjustable throttle
limiting screw. Speed limiting devices may be adjusted/
removed only by consumers when they determine that
their child is capable of handling the additional speed.
Per ANSI / SVIA-1-2010 (sec. 6.1) the unrestricted top
speed is 15 MPH or less for the 50cc Y-6 + models and
30 MPH or less for the 90cc Y-10+ models.
JUMPER RESTRICTED
CONDITION MAXIMUM SPEED
OF VEHICLE
Installed 10 MPH (16 km/h)
50C-
C Removed 15 MPH (24 km/h)

Installed 15 MPH (24 km/h)

90C-
C Removed 29 MPH (47 km/h)

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THROTTLE STOP SPEED CONTROL

SYSTEM
Use the following procedure to control how far the throttle
opens.

IMPORTANT
This procedure should be performed by consumers
2
only when they determine that their child is capable of
handling the additional speed.

1. Loosen the jam nut w.

2. Turn the screw e inward to reduce speed or outward
to increase speed.
3. Tighten the jam nut after adjusting.

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THROTTLE RELEASE SWITCH (TRS) TRS OPERATION

Always check the throttle for smooth operation before When the throttle is closed (idle) the throttle arm
riding. Periodically check the throttle free play. It should depresses a small micro switch that limits engine rpm.
be kept between 1/16” and 1/8” (1.5mm – 3.2mm).
If adjustment is required, loosen the jam nut and turn the
adjustment nut until the free play falls in to the
acceptable limit.

When the throttle lever is pushed forward the throttle arm

moves off the micro switch and allows the engine rpm to
increase with lever movement.
See: TRS Operation, page for information on TRS
Operation

If the throttle cable would become hung up or stuck while

the ATV is being operated, the spring loaded throttle arm
will return back and depress the micro switch, limiting
engine rpm.

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TRS SWITCH ADJUSTMENT CHOKE CABLE ADJUSTMENT

1. Slide the boot off the throttle cable adjuster and jam Verify free play of 1/16"-3/16" (1.6-4.76 mm) and
nut. smooth operation of choke cable.

Adjustments to the freeplay can be made by loosening

the choke cable adjustment in or out to gain the desired
freeplay.
2. Set parking brake.
3. Start engine and set idle to specified RPM.

NOTE
Be sure the engine is at operating temperature. See
“Idle Speed Adjustment.”

4. Loosen the adjustment nut on in–line cable adjuster.

If smooth choke operation is not obtainable, inspect

choke cable for kinks or sharp bends in routing.

5. Turn cable adjuster out until engine RPM begins to

increase.
6. Turn cable adjuster back in until throttle lever has
1/16” (.16 cm) of travel before engine RPM increases
7. Tighten lock nut securely and slide boot completely
in place to ensure a water–tight seal.

NOTE
Verify TRS switch plunger is held inward at idle
position.

8. Turn handlebars from left to right through the entire

turning range. If idle speed increases, check for
proper cable routing. If cable is routed properly and
in good condition, repeat adjustment procedure.

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IDLE SPEED ADJUSTMENT PILOT AIR SCREW

1. Start engine and warm it up thoroughly. CAUTION
2. Adjust idle speed by turning the slide adjustment The pilot air screw is calibrated at the factory to meet
screw in (clockwise) to increase or out EPA / CARB regulations for air quality standards. DO
(counterclockwise) to decrease RPM. (Refer to NOT adjust Pilot Air Screw. If the Pilot Air Screw is
illustration). altered from the factory setting, use the chart below to
return the screw back to base setting.

Idle Speed
50cc Mikuni: 1500 ± 100
90cc Keihin: 1700 ± 100
Pilot Air Screw Base Setting:
NOTE 50cc Mikuni: 2.5 turns out
90cc Keihin: 1.25 ± .5 turns out
Adjusting the idle speed affects throttle cable freeplay
and Throttle Release Switch (TRS) adjustment. Always
check throttle cable freeplay after adjusting idle speed
and adjust if necessary. VENT LINES
1. Check fuel tank, crankcase, carburetor, battery and
transmission vent lines for signs of wear,
FUEL LINES deterioration, damage or leakage. Replace every two
years.
1. Check fuel lines for signs of wear, deterioration,
damage, or leakage. Replace if necessary. 2. Verify vent lines are routed properly and secured
with cable ties.
2. Be sure fuel lines are routed properly and secured
with cable ties.
FUEL FILTER
The fuel filter should be replaced in accordance with the
IMPORTANT “Periodic Maintenance Chart” or whenever sediment is
Verify all fuel lines and vent lines are not kinked or visible in the filter.
pinched. Fuel Filter Location - Located in-line between fuel
valve and carburetor inlet.
3. Replace all fuel lines every two years.

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FUEL VALVE LOCATION

Outlaw 50 / Outlaw 90

To service the fuel filter:

1. Shut off fuel supply at fuel valve.
2. Remove line clamps at both ends of the filter.
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines.
5. Turn fuel valve to ‘ON’.
6. Start engine and inspect for leaks.

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Sportsman 90 CARBURETOR DRAINING

The carburetor float bowl should be drained periodically
to remove accumulated moisture or sediment from the
bowl, or before extended periods of storage.
1. Turn fuel valve to the ‘OFF’ position.
2. Place a container beneath the bowl drain hose.
3. Loosen drain screw and allow fuel in the float bowl
and fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.
6. Turn fuel valve to ‘ON’.
7. Check for fuel leaks.
8. Start engine and re–check for leaks.

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AIR FILTER SERVICE 6. Reinstall the screen, foam filter and air box cover.
Secure the clips.
1. Remove the seat.
7. Reinstall the seat.
2. Release the air box cover spring clips q and remove
the cover.
AIR BOX SEDIMENT TUBE
Periodically check the air box sediment tube located 2
toward the rear of the machine. Drain whenever deposits
are visible in the clear tube.

3. Remove the foam air filter w. Wash the foam filter in

warm soapy water, then rinse and let it dry. If the filter
is damaged, install a new foam filter. ITEM DESCRIPTION
4. Apply a commercially available foam filter oil to the
foam filter. q Hose Clamp
w Sediment Tube

NOTE
The sediment tube will require more frequent service if
the vehicle is operated in wet conditions or at high
throttle openings for extended periods.

1. Remove the hose clamp and remove the sediment

tube.
2. Drain and clean deposits from the tube.
3. Reinstall the tube and clamp.

5. Inspect the filter support screen e and clean away

any oil or sediments in the air box sediment drain r.

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ENGINE
ENGINE OIL LEVEL
Maintain the oil level within the safe range on the
dipstick. Do not overfill.
To check the oil level:
1. Position the vehicle on a level surface.
2. Remove the dipstick q. Wipe it dry with a clean cloth.

ITEM DESCRIPTION
q Engine Dipstick

w Oil “FULL” level

e Oil “ADD” level

3. Reinstall the dipstick completely.

4. Remove the dipstick and check the oil level. Verify
that the oil level is between w and e.
NOTE
Rising oil level between checks in cool weather driving,
can indicate moisture collecting in the oil reservoir. If
the oil level is over the full mark, change the oil.

5. Add the recommended oil as needed.

NOTE
Do not fill the over the normal oil operating range. Filling
over the normal operating range could cause a mist of
oil to enter the air box.

6. Reinstall the dipstick.

Recommended Engine Oil:
Engine oil recommendations are listed under Engine Oil
and Filter Change, page 2.19

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ENGINE OIL AND FILTER CHANGE 11. Remove the dipstick. Add 30 oz. (900 ml) of
recommended oil. Do not overfill.
1. Position the vehicle on a level surface.
Recommended Engine Oil:
2. Clean area around the drain plug.
Polaris Performance (PS-4) Synthetic Extreme Duty
3. Run engine two to three minutes until warm. 2878920 (1 Quart)
4. Stop the engine. 2878922 (2 Quart)
2878919 (1 Gallon)
2
CAUTION
Hot oil can cause burns to skin. Do not allow hot oil to 12. Reinstall the dipstick.
contact skin.
13. Start the engine. Allow it to idle for one to two
minutes.
5. Place a drain pan beneath the engine crankcase. 14. Stop the engine and inspect for leaks.
6. Remove the drain plug q and pre-filter screen r. 15. Check the oil level. Add oil as needed to bring the
Allow the oil to drain completely. level to the upper mark on the dipstick.

ITEM DESCRIPTION
q Drain Plug

w Drain Plug O-Ring

e Spring

r Pre-Filter Screen

7. Wash the oil pre-filter screen with solvent to remove

any debris. Allow the screen to air dry.
8. Inspect the O-ring on drain plug w, replace if needed.

NOTE
The sealing surfaces on the drain plug and crankcase
should be clean and free of burrs, nicks or scratches.

9. Reassemble the pre-filter screen r and spring e to

the pre-filter plug q.
10. Reinstall the pre-filter drain plug. Torque to
specification.

TORQUE
Engine Oil Plug:
11 ft-lbs (15 Nm)

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COMPRESSION / LEAKDOWN TEST

NOTE 4. If adjustment is required, loosen the locknut and turn
adjuster until the proper clearance is obtained.
Use of a compression tester adaptor that is too long
WILL CAUSE DAMAGE to the cylinder head. The
adaptor length should be no longer than the length of
the spark plug threads (1/2” or 12.07mm).

Cylinder Compression
Standard: 115 - 155 psi
Cylinder Leakage
Service Limit: 10%
Inspect if leakage exceeds 10% 5. When clearance is correct, hold adjuster screw and
tighten locknut securely.
6. Re-check the valve clearance.
VALVE CLEARANCE ADJUSTMENT 7. Repeat steps 3-5 to adjust the exhaust valve
1. Remove the valve cover caps and secondary air pipe clearance.
assembly to expose the intake and exhaust rocker Valve Clearance - In / Ex: .002" (.06 mm)
arms.

ENGINE MOUNTS
Inspect four engine mounts for cracks or damage.
Engine mounts are the points where the engine is
secured to the front and rear of the frame.

2. Remove spark plug and rotate engine to TDC on the

compression stroke.
3. Insert a .002” (.06 mm) feeler gauge between end of
intake valve stem and adjuster screw.

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ENGINE FASTENER TORQUE

Check engine fasteners and ensure they are tight. See
Engine Exploded Views & Torque Values, page 3.8 for
torque specifications.

CVT DRYING (90CC MODELS) 2

NOTE
If operating the ATV through water, be sure to check the
CVT and other components for water ingestion. The
ATV should be checked immediately.

There may be some instances when water is accidently

ingested into the CVT system. Use the following
instructions to dry it out before operating. The drain plug
is located on the bottom of the CVT cover.
1. Remove the drain plug located under the CVT
housing. Allow the water to drain. Reinstall the drain
plug.

2. Shift the transmission into neutral.

3. Start the engine. Apply varying throttle for 10-15
seconds to expel the moisture and air-dry the belt
and clutches. Do not hold the throttle wide open for
more than 3 - 4 seconds.
4. Allow the engine RPM to settle to an idle speed.
5. Test for belt slippage. If the belt slips, repeat the
process.

CAUTION
Exposure to salt water will cause corrosion to metal
components. If the vehicle is operated in salt water
areas, rinse it off frequently with fresh water.

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EXHAUST SPARK ARRESTOR CLEANING

Outlaw 50
WARNING
Exhaust system components are very hot during and
after use of the vehicle. Hot components can cause
burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away
from the exhaust system.
Never run an engine in an enclosed area.
Exhaust contains poisonous carbon monoxide gas that
can cause loss of consciousness or death. Operate the
engine in an open area or with an exhaust evacuation
system connected and functioning properly.
Wear eye protection.

The exhaust pipe must be periodically purged of

accumulated carbon as follows:
90 Sportsman / Outlaw
1. Remove the screws q and remove the arrestor
screen w from the end of the muffler.

ITEM DESCRIPTION
q Screw
w Arrestor Screen

2. Use a non-synthetic brush to clean the arrestor

screen. A synthetic brush may melt if components are
warm. If necessary, blow debris from the screen with
compressed air.
3. Inspect the screen for wear and damage. Replace if
necessary.
4. Reinstall the arrestor.
5. Torque the screws to specification.

TORQUE
Screws:
7 ft-lbs (9.5 Nm)

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TRANSMISSION AND FINAL DRIVE

TRANSMISSION LUBRICATION TRANSMISSION LUBRICANT LEVEL
The transmission lubricant level should be checked and The gear case fill plug is located on the side of the gear
changed in accordance with the maintenance schedule. case on the right side of the ATV. Maintain the lubricant
Remember to: level at the bottom of the fill plug hole threads. Fluids be
• Verify the vehicle is level before proceeding.
checked monthly and changed annually. 2
• Verify the vent hose is routed properly and is not 1. Position the vehicle on a level surface.
obstructed. 2. Remove the fill plug w.
• Follow instructions to check / change transmission
fluid.
TRANSMISSION SPECIFICATIONS
Recommended Lubricant:
Polaris (AGL)
ATV Gearcase Lubricant:
Quart - (PN 2878062)
Capacity:
11.8 oz. (350 ml)
or bottom of fill hole threads
Drain Plug Torque:
14 ft-lbs (19 Nm)

ITEM DESCRIPTION
w Transmission Fill Plug

e Transmission Drain Plug

3. View the lubricant level through the fill hole.

4. If the level is low, add the recommended lubricant.
5. Reinstall the fill plug w.

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TRANSMISSION LUBRICANT CHANGE DRIVE CHAIN INSPECTION - 90CC MODELS

1. Check the amount of chain slack by moving the
1. Position the vehicle on a level surface.
vehicle slightly forward to gain chain deflection.
2. Remove the fill plug w.
2. Collapse the suspension by applying downward
3. Place a drain pan beneath the transmission. force to the rear suspension of the vehicle.
4. Remove the drain plug e and allow the lubricant to
3. Compress the suspension to create a straight sight-
drain completely.
line between the rear axle and the gear case output
IMPORTANT shaft. This establishes the tightest chain position.

DO NOT remove either the CVT drain plug or Shifter

Detent r.

4. Pull down on the tensioner to move it out of the way,

then measure the chain deflection. Allowable chain
deflection is 1/4”-1/2” (6-12 mm).
5. Clean and reinstall the drain plug e. Torque to
specification. DRIVE CHAIN INSPECTION - 50CC MODELS
1. Check the amount of chain slack by moving the
TORQUE vehicle slightly forward to gain deflection at the top of
Transmission Drain Plug: the chain.
14 ft-lbs (19 Nm)

6. Add the recommended lubricant. Maintain the

lubricant level at the bottom of the fill plug hole
threads.
7. Reinstall the fill plug. Check for leaks.

FLUID CAPACITY
Polaris (AGL) ATV Gearcase Lubricant:
11.8 oz. (350 ml)
or bottom of transmission fill hole threads

2. The chain should have 1/4”-1/2” (6-12 mm)

deflection. If the chain needs adjustment, use the
following procedure.

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DRIVE CHAIN ADJUSTMENT - 50 AND 90CC MODELS

1. Loosen the four rear bearing housing mount bolts. 5. Tighten the four bearing housing bolts q to
specification and reinstall the rear cover.

2. Loosen the chain adjuster lock nut.

3. Turn the chain adjuster clockwise until chain tension
is set to specification. TORQUE
4. Tighten the chain adjuster lock nut to specification Chain Adjuster Lock Nut: 84 in-lbs (9.4 Nm)
and verify the chain tension is at specification. Bearing Housing Bolts: 43 ft-lbs (60 Nm)

SPROCKET INSPECTION
Inspect the front and rear sprockets w for worn, broken
or bent teeth.

To check for wear, pull upward on the chain at the top of

the rear sprocket. Replace sprocket if chain movement
exceeds 1/4” (.6 cm)

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ELECTRICAL AND IGNITION SYSTEM

BATTERY MAINTENANCE SERVICE NOTES BATTERY REMOVAL - 50CC

WARNING WARNING
CALIFORNIA PROPOSITION 65 WARNING: Batteries, Improperly connecting or disconnecting battery cables
battery posts, terminals and related accessories contain can result in an explosion and cause serious injury or
lead and lead compounds, and other chemicals known death. When removing the battery, always disconnect
to the State of California to cause cancer and birth the negative (black) cable first. When reinstalling the
defects or other reproductive harm. WASH HANDS battery, always connect the negative (black) cable last.
AFTER HANDLING.Battery electrolyte is poisonous. It
contains acid! Serious burns can result from contact 1. Remove the (3) bolts securing the battery bracket to
with the skin, eyes, or clothing. the frame and remove the battery and bracket from
ANTIDOTE the frame.
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
a physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using
in closed space. Always shield eyes when working near
batteries.
Keep out of reach of children.

New batteries must be fully charged before use or

battery life will be significantly reduced (10-30% of the
battery’s full potential). 2. Remove the (2) nuts securing the hold-down strap
on the battery.
NOTE
DO NOT use a constant high-amperage battery
charger. Use a low-amperage charger capable of
charging voltage that is 1/10 of the battery amp-hour
rating.

3. Disconnect the black negative (-) battery cable first.

4. Disconnect the red positive (+) battery cable next.
5. Remove the battery from the ATV.

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BATTERY REMOVAL - 90CC BATTERY INSTALLATION

1. Place the fully charged battery in its holder.
WARNING
2. Attach the hold-down strap(s).
Improperly connecting or disconnecting battery cables
can result in an explosion and cause serious injury or 3. Connect and tighten the red positive (+) cable first.
death. When removing the battery, always disconnect
the negative (black) cable first.
4. Connect and tighten the black negative (-) cable last. 2
5. Verify that the cables are properly routed.
When reinstalling the battery, always connect the
negative (black) cable last.
TORQUE
Battery Terminal Bolts:
1. Remove the seat to access the battery. 50 in-lbs (6 Nm)

NOTE
When installing a new battery, make sure it's fully
charged prior to its initial use. Using a new battery that
has not been fully charged can damage the battery and
result in a shorter life. It can also hinder vehicle
performance. If charging is necessary, use a .5 amp
battery charger.

BATTERY STORAGE
Whenever the vehicle is not used for a period of three
months or more, remove the battery from the vehicle,
ensure that it's fully charged, and store it out of the sun in
2. Disconnect the hold-down strap securing the battery a cool, dry place. Check battery voltage each month
in position. during storage and recharge as needed to maintain a full
3. Disconnect the black negative (-) battery cable first. charge.
4. Disconnect the red positive (+) battery cable last. For battery removal, See:Battery Removal, page
5. Lift the battery out of the compartment.

CAUTION
To reduce the chance of sparks: Whenever removing
the battery, disconnect the negative (black) cable first.
When reinstalling the battery, install the negative cable
last.

BATTERY CLEANING
Keep the battery terminals and connections free of
corrosion. If cleaning is necessary, remove the corrosion
with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.

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FUSES / FUSE HOLDER LOCATION

A 7 Amp fuse protects the main electrical system on all
youth models. See illustrations for fuse locations.

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SPARK PLUG INSPECTION 6. If necessary, replace spark plug with proper type.

1. Remove spark plug high tension lead. Clean plug CAUTION

area so no dirt and debris can fall into engine when
Severe engine damage may occur if the incorrect
plug is removed.
spark plug is used.

Recommended Spark Plug:

2
NGK CR6HSA

7. Apply a small amount of anti-seize compound to the

spark plug threads.
8. Install spark plug and torque to specification.

TORQUE
Spark Plug:
104 in-lbs (12 Nm)
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup. Look
for a sharp outer edge with no rounding or erosion of
the electrodes.
IGNITION TIMING
Timing is CDI controlled and has no adjustment
procedure.

NOTE
There are no timing advance marks stamped on the
flywheel to read with a timing light.

Ignition Timing:17.5° BTDC @ 1700 RPM

4. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only.
ENGINE / FRAME GROUND
CAUTION Inspect engine-to-frame ground cable connection at the
A wire brush or coated abrasive should not be used. starter motor mount. Be sure it is clean and tight.

5. Measure gap with a wire gauge. Refer to

specifications for proper spark plug type and gap.
Adjust gap if necessary by bending the side electrode
carefully.

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STEERING AND SUSPENSION

STEERING 50cc models
The steering components should be checked periodically
for loose fasteners, worn tie rod ends, and damage. Also
check to make sure all cotter pins are in place. If cotter
pins are removed, they must not be re-used. Always use
new cotter pins.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.

WARNING
All steering component adjustment and repair should
be performed by a certified Polaris Master Service
Dealer (MSD) technician who has received the proper
training and understands the procedures outlined in this
manual. Use only genuine Polaris replacement parts.

NOTE
Whenever steering components are replaced, check
front end alignment. Use only genuine Polaris parts.
90cc models

ITEM TORQUE

q 16 ft-lbs (22 Nm)

w 25 ft-lbs (34 Nm)

e 40 ft-lbs (54 Nm)

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TIE ROD END / STEERING INSPECTION 5. Repeat inspection for inner tie rod end (on steering
post).
1. Elevate front end of ATV so front wheels are off the
ground. Check for any looseness in front hub / wheel
assembly by grasping the tire firmly at top and bottom
first, and then at front and rear. Try to move the wheel
and hub by pushing inward and pulling outward.
2

6. Replace any worn steering components. Steering

should move freely through entire range of travel
without binding.

WHEEL ALIGNMENT

WARNING
2. If abnormal movement is detected, inspect the hub Severe injury or death can result from improper
and wheel assembly to determine the cause. toe alignment and adjustment.
3. Remove the front wheels. All tie rod adjustments should be performed
by an authorized Polaris dealer.
4. Grasp the steering tie rod and pull in all directions
feeling for movement in the tie rod end.
Use the following procedure to check the toe alignment
of the vehicle. The recommended toe alignment is 1/8” to
1/4” (3-6 mm) toe out.

1. Set the handlebars in a straight-ahead position.

NOTE
The steering arm can be used as an indicator of
whether the handlebars are straight. The arm should
always point straight back from the steering post.

2. Place the stands in front of the vehicle, perpendicular

to the rear tires.
3. Tie an elastic string around the stands, making sure
the string just touches the side surface of the rear
tires on each side of the vehicle and goes around the
stands in front of the vehicle.

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4. Measure the distance from the string to the rim at the TOE ADJUSTMENT
front and rear of the front rim q. Rear measurement If toe alignment is incorrect, measure the distance
should be 1/16” - 1/8” (2-3 mm) more than the front between vehicle center and each wheel. This will tell you
measurement. which tie rod needs adjusting.

NOTE
Be sure the handlebars are straight ahead before
determining which tie rod(s) need adjustment.

CAUTION
During tie rod adjustment, it is very important that the
following precautions be taken when tightening tie rod
end jam nuts.
If the rod end is positioned incorrectly it will not pivot,
and may break

1. Hold tie rod end to keep it from rotating.

2. Loosen jam nuts at both end of the tie rod.
3. Shorten or lengthen the tie rod until alignment is as
required to achieve the proper toe setting of zero.

IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and
premature wear. Damage may not be immediately
apparent if done incorrectly. See illustration.

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FRONT SUSPENSION INSPECTION SUSPENSION SPRING ADJUSTMENT

Compress and release front suspension. Damping The rear spring preload can be adjusted on both 50cc
should be smooth throughout the range of travel. Inspect and 90cc models. The front spring preload can be
the front shocks and springs to ensure proper function. If adjusted on only 90cc models. To make preload
the shock is leaking oil, replace it. adjustments, turn the adjuster cam to increase or
decrease the amount of preload.
Check all front suspension components for wear or
damage. Check shock mounting fasteners to ensure they
2
are tight. Inspect A-arm and weldments for any sign of
damage.

REAR SUSPENSION INSPECTION

Compress and release rear suspension. Damping should
be smooth throughout the range of travel.
• Check all rear suspension components for wear or
damage. Shock Spanner Wrench:(PN 2870872)
• Inspect shock for leakage.

Inspect the rear shock and spring to ensure proper

function. If the shock is leaking oil, replace it. Inspect the
swing arm and weldments for any sign of damage.

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BRAKE SYSTEM
BRAKE SYSTEM INSPECTION BRAKE FREEPLAY
The following checks are recommended to keep the Measure the free-play of the front and rear brakes at the
brake system in good operating condition. Service life of intervals recommended in the Periodic Maintenance
brake system components depends on operating Chart. If the freeplay isn’t at specification, adjust the
conditions. Inspect brakes in accordance with the freeplay as outlined below.
maintenance schedule and before each ride.

BRAKE LEVER TRAVEL

Check brake lever travel at the intervals recommended in
the Periodic Maintenance Chart. Service the brakes
when brake lever travel reaches the total lever travel
measurement listed in the table below. Always service
the brakes when there is no longer sufficient stopping
ability at the specified lever travel setting

Brake Freeplay Specifications

MODEL FRONT BRAKE REAR BRAKE
110cc .08-.12” (2-3 mm) .08-.12” (2-3 mm)
Models

COMPONENT TOTAL LEVER TRAVEL

Front brake lever 1.75" (45 mm)

Rear brake lever 2.5" (65 mm)

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FRONT BRAKE ADJUSTMENT 6. While rotating the right front wheel, tighten the lower
front brake adjuster nut e on the right-hand control.

MEASUREMENT
7. When you begin to feel a slight drag on wheel
rotation, loosen the adjuster nut one full turn.
q 1/16” — 1/8” (1.5 — 3.2mm)
8. Verify that the right hand brake functions correctly.
9. Verify that brake lever freeplay is at specification.
1. Position the vehicle on a level surface. 10. Carefully lower the vehicle to the ground.
2. Shift the transmission into neutral.
MEASUREMENT
3. Elevate the front of the vehicle by placing a suitable
stand under the frame. The front tires should be Brake Cable Free Play
slightly off the ground. .08" - .12" (2 - 3 mm)
4. While rotating the left front wheel, tighten the upper
front brake adjuster nut w on the right-hand control.

5. When you begin to feel a slight drag on wheel

rotation, loosen the adjuster nut one full turn.

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REAR BRAKE ADJUSTMENT 8. Carefully lower the vehicle to the ground.

1. Position the vehicle on a level surface. Brake Cable Free Play

2. Shift the transmission into neutral (if applicable). .08" - .12" (2 - 3 mm)
3. Elevate the rear of the vehicle by placing a suitable
stand under the frame. The rear tires should be
slightly off the ground. BRAKE SHOE INSPECTION
4. While rotating the rear wheels, hold the square Brake shoes should be changed when friction material is
portion of the cable q and tighten the rear brake wing worn to service limit. See General Specifications, page
nut w at the rear brake drum. .

5. When you begin to feel a slight drag in wheel rotation,

loosen the wing nut one full turn.
6. Verify that the left hand brake functions correctly.

7. Verify that brake freeplay is at specification.

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WHEELS AND TIRES

WHEEL, HUB AND SPINDLE TORQUE
TABLE
ITEM SPECIFICATION
Front Wheel Bolts 22 ft-lbs (30 Nm) 2
Rear Wheel Bolts 22 ft-lbs (30 Nm)
Front Spindle Nut 44 ft-lbs (59 Nm)

Rear Hub Retaining Nut 58 ft-lbs (79 Nm)

WHEEL INSPECTION
Inspect all wheels for runout or damage.
Inspect the front and rear wheel bolts for tightness. Re-
torque the wheel bolts periodically and check before
each ride.

NOTE
Do not over tighten the wheel bolts.

WHEEL REMOVAL - FRONT / REAR

1. Stop the engine, place the transmission in gear and
lock the parking brake.
2. Loosen the wheel bolts slightly.
3. Elevate the side of the vehicle by placing a suitable
stand under the footrest frame.
4. Remove the wheel bolts and remove the wheel.

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WHEEL INSTALLATION - FRONT / REAR 2. Install the wheel bolts and finger tighten them.
3. Lower the vehicle to the ground.
1. With the transmission in gear and the parking brake
locked, place the wheel in the correct position on the 4. Securely tighten the wheel bolts to specification.
wheel hub. Be sure the valve stem is toward the
outside and rotation arrows on the tire point toward
forward rotation.
FRONT WHEEL REAR WHEEL

ITEM DESCRIPTION TORQUE

q Cotter Key —

w Front Spindle Nut 44 ft-lbs (59 Nm)

e Front Wheel Bolts 22 ft-lbs (30 Nm)

r Rear Hub Nut 58 ft-lbs (79 Nm)

t Rear Wheel Bolts 22 ft-lbs (30 Nm)

CAUTION
Improper tire inflation or the use of non-standard size or
type of tires may adversely affect vehicle handling,
which could result in vehicle damage or personal injury.
Always maintain proper tire pressure. When replacing
tires, always use original equipment size and type.

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TIRE PRESSURE
Tire Pressure Inspection (PSI - Cold)
MODEL FRONT / REAR
Sportsman 90 3 psi / 3 psi (20.7 kPa) 2
Outlaw 90 3 psi / 3 psi (20.7 kPa)

Outlaw 50 2 psi / 2 psi (13.8 kPa)

TIRE INSPECTION
• Improper tire inflation may affect vehicle
maneuverability.
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect
vehicle handling.

MEASUREMENT
Tire Lug Service Limit:
Replace if 1/8″ (3 mm) or less.

WARNING
Operating with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident. Always replace tires
when the usable tread depth has worn out.

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NOTES

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CHAPTER 3
ENGINE / TRANSMISSION
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
ENGINE SERVICE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
ENGINE EXPLODED VIEWS & TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
OIL FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3
PISTON / RING IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
ACCESSIBLE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
ENGINE INSTALLATION NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
ENGINE BREATHER / OIL SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
ENGINE BREATHER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
CYLINDER DIVIDER PLATE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
FINDING TOP DEAD CENTER (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
TOP-END DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
CYLINDER HEAD GASKET COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
ENGINE DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
CAM CHAIN TENSIONER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
CAM CHAIN TENSIONER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
ROCKER ARM DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
CYLINDER HEAD SURFACE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
COMBUSTION CHAMBER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32
CAM CHAIN TENSIONER BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.32
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
CYLINDER HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
HONING TO DEGLAZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
BOTTOM-END DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37
FLYWHEEL REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

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STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.37

OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
CRANKSHAFT / CAM CHAIN / SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
CRANKCASE OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.41
PISTON INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
TENSIONER BLADE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CYLINDER HEAD & CAMSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
CAM CHAIN TENSIONER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.46
EXHAUST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
SPARK ARRESTOR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
HEAT SHIELD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.48
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
TRANSMISSION DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
TRANSMISSION SHIFTER GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
STARTER DRIVE MECHANISM (ELECTRIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
KICK START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
KICK START DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.61
KICK START ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
SPARK PLUG FOULING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65
ENGINE (GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.65

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ENGINE SERVICE
SPECIAL TOOLS
2870390 PA-45153 PA-48701

Piston Support Block Flywheel Puller Adaptor, Valve Spring Compressor

PV-1253 2200634

Valve Spring Compressor Valve Seat Reconditioning Kit

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ENGINE / TRANSMISSION

ENGINE SERVICE DATA

CYLINDER HEAD / VALVETRAIN OUTLAW 50
Rocker arm ID (In/Ex) Std .3937 - .3944" (10.00-10.02 mm)
Rocker Arm
Rocker arm ID (In/Ex) Limit .3976" (10.10 mm)

Rocker arm shaft OD (In/Ex) Std .3926 - .3932" (9.97 - 9.99 mm)
Rocker Arm Shaft
Rocker arm shaft OD (In/Ex) Limit .3902" (9.91 mm)

Std 1.047" (26.60 mm)

In
Limit 1.031" (26.20 mm)
Camshaft Cam lobe height
Std 1.039" (26.40 mm)
Ex
Limit 1.024" (26.00 mm)
Cylinder Head Surface warpage limit .0020" (.05 mm)

In Std .002" (.06 mm)

Valve Clearance (Lash)
Ex Std .002" (.06 mm)

Std .039" (1.0 mm)

In
Limit .063" (1.6 mm)
Valve Seat Contacting width
Std .039" (1.0 mm)
Ex
Limit .063" (1.6 mm)

In .1958 - .1965" (4.98 - 4.99 mm)

Valve Stem diameter Ex .1950 - .1956" (4.96 - 4.97 mm)

Limit .1930" (4.90 mm)

In .1968 - .1973" (5.0 - 5.01 mm)

Valve Guide Inner Diameter Ex .1968 - .1973" (5.0 - 5.01 mm)

Limit .1980" (5.03 mm)

Clearance (Standard) In .0004 - .0015" (.01 - .037 mm)
Clearance (Standard) Ex .0012 - .0022" (.03 - .057 mm)
Valve Stem to Guide
Clearance Limit (In) .0031" (.08 mm)
Clearance Limit (Ex) .0039" (.10 mm)

Inner 1.270" (31.75 mm)

Free Length
Valve Spring Outer 1.365" (34.67 mm)
SquarenessInner 0.075" (1.9 mm)

Cam Chain Install new as a part of any crankshaft service

Compression Pressure (Maximum reading with throttle wide open) Std 115-155 psi (790-1080 kPa )
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off

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CYLINDER / PISTON / CONNECTING ROD OUTLAW 50

Surface warpage limit (mating with cylinder head) .002" (.05 mm)

Cylinder bore Std 1.5354 - 1.5358" (39.00 - 39.01 mm)

Taper limit .002" (.05 mm)

Cylinder Out of round limit .002" (.05 mm)

Std .0004 - .0014" (.01 - .04 mm)

Piston to cylinder clearance
Limit .0039" (.1 mm)

Boring Limit 2nd Oversize (+ .0197" / .50 mm) 3

Std 1.5344 - 1.5350" (38.975 - 38.99 mm)
Outer diameter
(Measure 3mm up from bottom 1st O.S. .0098" (.25 mm) Oversize
Piston and 90° to piston pin)
2nd O.S. .0197" (.50 mm) Oversize

Pin Bore .5122 - .5129" (13.01 - 13.03 mm)

Pin to piston pin bore clearance .0002 - .0005" (.004 - .012 mm)
Piston Pin
Pin Diameter .5117 - .5118" (12.997-13.00mm) (Limit: 12.96mm)

Std .002 - .008" (.05 - .20 mm)

Top ring
Limit .020" (0.5 mm)

Std .002 - .008" (.05 - .20 mm)

Second
Piston Ring Piston Ring Installed gap
ring
Limit .020" (0.5mm)

Std .0118 - .0354" (.3 - .9 mm)

Oil ring
Limit .059" (1.5 mm)

Std .0008 - .0024" (.02 - .06 mm)

Top ring
Limit .0035" (.09 mm)
Standard clearance -
Piston Ring
piston ring to ring groove
Std .0008 - .0024" (.02 - .06 mm)
Second
ring
Limit .0035" (.09 mm)

Std .5122" - .5129" (13.01 - 13.03 mm)

Connecting rod small end ID
Limit .5141" (13.06 mm)
Connecting Rod
Connecting rod big end axial clearance Std .004 - .012" (0.1 - 0.3 mm)

Connecting rod big end radial clearance Std .0002 - .0005" (0.002 - 0.013 mm)

Crankshaft end runout 0.0016" (0.04 mm)

Crankshaft
Crankshaft end runout - limit 0.0039" (0.1 mm)

Cam Shaft Chain Install new as a part of any crankshaft service

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side

PTO: Power Take Off.

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ENGINE / TRANSMISSION

CYLINDER HEAD / VALVETRAIN SPORTSMAN 90 / OUTLAW 90

Rocker arm ID (In/Ex) Std .3937 - .3944" (10.00-10.02 mm)
Rocker Arm
Rocker arm ID (In/Ex) Limit .3976" (10.10 mm)

Rocker arm shaft OD (In/Ex) Std .3926 - .3932" (9.97 - 9.99 mm)
Rocker Arm Shaft
Rocker arm shaft OD (In/Ex) Limit .3902" (9.91 mm)

Std 1.047" (26.60 mm)

In
Limit 1.031" (26.20 mm)
Camshaft Cam lobe height
Std 1.039" (26.40 mm)
Ex
Limit 1.024" (26.00 mm)

Cylinder Head Surface warpage limit .0020" (.05 mm)

In Std .002" (.06 mm)

Valve Clearance (Lash)
Ex Std .002" (.06 mm)

Std .039" (1.0 mm)

In
Limit .063" (1.6 mm)
Valve Seat Contacting width
Std .039" (1.0 mm)
Ex
Limit .063" (1.6 mm)

In .1958 - .1965" (4.98 - 4.99 mm)

Valve Stem diameter Ex .1950 - .1956" (4.96 - 4.97 mm)

Limit .1930" (4.90 mm)

In .1968 - .1973" (5.0 - 5.01 mm)

Valve Guide Inner Diameter Ex .1968 - .1973" (5.0 - 5.01 mm)

Limit .1980" (5.03 mm)

Clearance (Standard) In .0004 - .0015" (.01 - .037 mm)

Clearance (Standard) Ex .0012 - .0022" (.03 - .057 mm)

Valve Stem to Guide
Clearance Limit (In) .0031" (.08 mm)

Clearance Limit (Ex) .0039" (.10 mm)

Inner 1.270" (31.75 mm)

Free Length
Valve Spring Outer 1.365" (34.67 mm)

SquarenessInner 0.075" (1.9 mm)

Cam Chain Install new as a part of any crankshaft removal

Compression Pressure (Maximum reading with throttle wide open) Std 135-175 psi (930-1205 kPa )

KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;

PTO: Power Take Off

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CYLINDER / PISTON / CONNECTING ROD SPORTSMAN 90 / OUTLAW 90

Surface warpage limit (mating with cylinder head) .002" (0.05 mm)

Cylinder bore Std 1.8504 - 1.8507" (47.00 - 47.01 mm)

Taper limit .002" (0.05 mm)

Cylinder Out of round limit .002" (0.05 mm)

Std .0004 - .0014" (0.01 - 0.04 mm)

Piston to cylinder clearance
Limit .0039" (0.1 mm)

Boring Limit 2nd Oversize (+ .0197" / .50 mm) 3

Std 1.8492 - 1.8500" (46.97 - 46.99 mm)
Outer diameter
(Measure 5mm up from bottom 1st O.S. .0098" (.25 mm) Oversize
Piston and 90° to piston pin)
2nd O.S. .0197" (.50 mm) Oversize

Pin Bore .5122 - .5129" (13.01 - 13.03 mm)

Pin to piston pin bore clearance .0002 - .0005" (.004 - .012 mm)
Piston Pin
Pin Diameter .5117 - .5118" (12.997-13.00mm) (Limit: 12.96mm)

Std .002 - .008" (.10 - .25 mm)

Top ring
Limit .020" (0.5 mm)

Std .002 - .008" (.3 - 0.45 mm)

Second
Piston Ring Piston Ring Installed gap
ring
Limit .020" (0.5mm)

Std .012 - .035" (0.2 - 0.7 mm)

Oil ring
Limit .059" (1.5 mm)

Std .0008 - .0024" (0.02. - 06 mm)

Top ring
Limit .0035" (0.09 mm)
Standard clearance -
Piston Ring
piston ring to ring groove
Std .0008 - .0024" (0.02 - 0.06 mm)
Second
ring
Limit .0035" (0.09 mm)

Std .5122" - .5129" (13.01 - 13.03 mm)

Connecting rod small end ID
Limit .5141" (13.06 mm)
Connecting Rod
Connecting rod big end axial clearance Std .004 - .012" (0.1 - 0.3 mm)

Connecting rod big end radial clearance Std .0002 - .0005" (0.002 - 0.013 mm)

Crankshaft end runout 0.0016" (0.04 mm)

Crankshaft
Crankshaft end runout - limit 0.0039" (0.1 mm)

Oil Pump Chain

Install new as a part of any oil pump replacement
Cam Shaft Chain
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;

PTO: Power Take Off

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ENGINE EXPLODED VIEWS & TORQUE

VALUES

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ENGINE / TRANSMISSION

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 ENGINE / TRANSMISSION

OIL FLOW DIAGRAM

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ENGINE / TRANSMISSION

PISTON / RING IDENTIFICATION ACCESSIBLE COMPONENTS

The letters “IN” or the larger of two valve pockets on the
piston face the intake side of the engine (UP). Other NOTE
numbers may be used for size identification. Generally, The top-end of the engine can be serviced without
four stroke engine rings have a rectangular profile. The pulling the engine from the ATV. Loosen the upper
numbers or letters on all rings must be positioned steering post mounting bolts to allow enough clearance
upward. Un-marked rings (such as oil control ring rails) to remove cylinder head and cylinder.
are non directional. Always see ring installation text for However, it is recommended to pull the engine to
specific ring information. service top-end components.

The following components can be serviced or removed

with the engine installed in the frame:

• Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Oil pump
• Carburetor
• Transmission

The following components require engine removal for

service:

• Cam Chain and Cam Chain Drive (Lower) Sprocket

• Cylinder Head
• Rocker Arms / Shafts
• Cylinder
• Piston / Rings
• Camshaft
• Crankshaft
• Crankshaft Main Bearings
• Crankcase
• Valves

NOTE
Crankshaft components are not serviceable. Replace
crankshaft as an assembly.

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 ENGINE / TRANSMISSION

ENGINE REMOVAL 8. Disconnect or Remove From LEFT Side:

1. Clean the ATV and work area thoroughly.
• CVT Air Ducts
2. Remove seat. • Brake line retainer bracket (50 cc only)
3. Remove front cab and foot rests. • Breather Hose (To Valve Cover)

4. Disconnect battery cables.

5. Drain engine oil and / or transmission oil as required
for the service to be performed. Engine Oil and Filter 9. Remove two engine mount bolts at the front and one
Change, page 2.19 rear engine mount bolt.
6. Disconnect or remove from RIGHT Side: 10. Check for any remaining attachments and remove
engine from right side of frame.
• Exhaust Pipe
• Spark Plug Wire
• Drive Sprocket Cover / Sprocket / Chain
• Starter Motor
• Wire Connector - Stator and Neutral Switch
• Carburetor / Manifold
• Breather Hose

7. Cover any openings with a clean shop towel.

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ENGINE INSTALLATION NOTES

After the engine is installed in the frame, review this
checklist and perform all steps that apply:
General Items

• Install previously removed components using new

gaskets, seals, and fasteners where applicable.
• Perform checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the
Pre-Ride - 10 Hour Maintenance Interval, page
checklist.

CVT System

• Clean clutch sheaves thoroughly and inspect inlet

and outlet ducts for proper routing and sealing.

Transmission Adjustment (If required)

• Before tightening the gear selector bracket screws

on the transmission, be sure transmission is in
neutral and center the lever in the neutral slot on
bracket. Inspect operation and re-adjust bracket if
necessary.

Exhaust

• Replace exhaust gaskets.

Engine Mount Torque

• Front mounts (2)

36 in-lbs (4 Nm)
• Rear mount (1)
18 in-lbs (2 Nm)

Engine Break In Period

4 Cycle Engine Break-In Period is defined as the first

10 hours of engine operation or 2 full tanks of fuel.
• Use Polaris Performance (PS-4) Synthetic
Extreme Duty oil during break-in period or after
engine top end service, to ensure complete piston
ring seating to cylinder wall. Change to
recommendation after 10 hours.
• Use fuel with a minimum octane of 87 (R+M)/2
method.
• Check oil level before each ride, especially during
the break-in period.
• Change engine oil and filter after the first 10 hours of
operation.

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ENGINE LUBRICATION ENGINE BREATHER / OIL SEPARATOR

The engine breather / oil separator is located on the left
PART NO. SIZE OIL TYPE:** side. The breather provides ventilation for the cylinder
2878920 1 Quart head and crankcase through the air box.
Polaris Performance
2878922 2 Quart (PS-4) Synthetic
Extreme Duty
2878919 1 Gallon

Capacity: 30 oz. (900 ml)

Drain Plug (Engine Oil): 11 ft-lbs (15 Nm)
Oil Pressure Specification: Not Applicable 3
** For break-in period after engine top end service, use
Polaris Performance (PS-4) Synthetic Extreme Duty
oil to ensure complete piston ring seating to cylinder wall.
Change to above recommendation after 10 hours.

TRANSMISSION LUBRICATION
Oil Type:
Polaris AGL ATV Gearcase Lubricant
1 Quart - (PN 2878068)
Capacity: Approximately 11.8 oz. (350 ml)
Drain Plug (Transmission): 14 ft-lbs (19 Nm) ENGINE BREATHER REPLACEMENT
1. Remove 8mm through bolt from right hand side of
engine.

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2. Remove breather hose clamp and breather hose. 7. Reconnect breather hose and breather hose clamp.

CYLINDER DIVIDER PLATE REPLACEMENT

1. Remove 8mm through bolt from right hand side of
engine.

3. Using gasket scraper, remove and discard the old

gasket.

2. Remove breather hose clamp and breather hose.

4. Install new gasket.

5. Install engine breather assembly.
6. Torque through bolt to specification.

3. Bend three tabs back revealing screws.

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4. Remove three screws.

5. Remove the cylinder divider plate.

6. With gasket scraper tool, remove gasket on backside
of cylinder divider plate and replace.

7. Install cylinder divider plate.

8. Install three screws and torque to specification.
9. Bend tabs over screws.
10. Install engine breather assembly.
11. Torque through bolt to specification.
12. Reconnect breather hose and breather hose clamp.

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FINDING TOP DEAD CENTER (TDC) USING THE FLYWHEEL TIMING MARK
Top Dead Center (TDC) is referenced throughout this 1. Remove timing hole plug from flywheel cover.
section.
2. Rotate the engine in normal direction of rotation and
Properly locate TDC on compression stroke prior to: watch the intake valve open and then close.
3. View straight into the timing hole and continue
• Top end disassembly or assembly rotating engine until the indicator line nearest the “T”
• Timing the cam shaft mark on flywheel t aligns with the groove in the
• Valve clearance inspection / adjustment timing hole y. There should be clearance on both
valves.
Two methods of finding TDC are shown below.
USING THE CAMSHAFT SPROCKET TIMING MARK
1. Remove bolt q and camshaft sprocket cover w.

2. Rotate engine to align dot e on sprocket with mark

r on top of head. Mark and dot should form a
straight line through the center of camshaft and
sprocket bolt as shown.

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TOP-END DISASSEMBLY
CYLINDER HEAD GASKET COVER CAM CHAIN TENSIONER REMOVAL
REMOVAL
NOTE
1. Remove four 10mm fasteners.
Tensioner can be removed with engine in frame.

1. Find TDC on compression stroke. Finding Top Dead

Center (TDC), page
2. Remove camshaft tensioner cap with spring e.
3

2. Remove gasket with gasket scraper and discard.

3. Replace gasket.
4. Install cover and fasteners.
5. Torque fasteners to specification.

ENGINE DISASSEMBLY
REMOVE:
3. Remove tensioner body bolts r.
1. Engine from frame.
2. Bolt q and camshaft cover. Top cover nuts w.

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CAM CHAIN TENSIONER INSPECTION CYLINDER HEAD REMOVAL

REMOVE:
1. Pull plunger out of tensioner body until fully extended.
Closely inspect teeth on pawl t and on plunger y.
1. Bolt q.
2. Nuts w evenly in a cross pattern until loose.
3. Cam sprocket bolts e.

2. Hold ratchet pawl back, and push plunger in and out

of tensioner body. The plunger should move smoothly
through the travel range.
4. Slide sprocket off end of camshaft.
3. Replace tensioner assembly if any part is worn or
damaged. 5. Lift cylinder head off studs.

6. Secure cam chain with a wire to prevent it from falling

into crankcase.

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ROCKER ARM DISASSEMBLY / INSPECTION

NOTE 3. Inspect pad surface r of rocker arm for wear.
Replace both camshaft and rocker arms if wear is
Cylinder head must be removed to service the rocker visible.
arms.

IMPORTANT
Mark or tag rocker arms and shafts to keep them in
order for assembly.
3
REMOVE:
1. Right cylinder head cover. Pull rocker shaft using a
bolt.

4. Measure O.D. of rocker shaft in 3 places t.

5. Measure I. D. of rocker arm y and compare to
specification.
6. Inspect rocker adjuster screws u and the end of the
valve stems for wear, pitting, or damage to threads of
the adjuster or locknut. Replace all worn or damaged
parts.

2. Rocker arm.

NOTE
Adjuster face is hardened and cannot be ground or
refaced.

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CAMSHAFT REMOVAL CAMSHAFT INSPECTION

1. Rocker arms must be removed from cylinder head to 1. Inspect cam sprocket teeth for wear or damage.
remove the camshaft. Replace if necessary.
2. Slide camshaft out left side of cylinder head.

2. Visually inspect each cam lobe w and bearing e for

wear, chafing or damage.

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ITEM DESCRIPTION
r Intake Rocker Shaft

t Exhaust Rocker Shaft

MEASUREMENT
Cam Lobe Height
Intake Std:
1.047² (26.60 mm)
Limit:
1.031² (26.20 mm)
Exhaust Std:
1.039” (26.40 mm)
Limit:
1.024” (26.00 mm)

3. Thoroughly clean the cam shaft.

4. Thoroughly clean the cam shaft to be sure all oil
passages are clear.
Replace camshaft if damaged or if any part is worn
excessively.

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CYLINDER HEAD INSPECTION COMBUSTION CHAMBER INSPECTION

Thoroughly clean cylinder head surface to remove all Clean all accumulated carbon deposits from combustion
traces of gasket material and carbon. chamber and valve seat area with a soft wire brush.
Inspect the combustion chamber for cracks and/or
CAUTION damage from foreign debris.
Use care not to damage sealing surface. If there is
damage found on the cylinder head combustion
chamber, it is recommended the component be
replaced.

CYLINDER HEAD SURFACE INSPECTION

Lay a straight edge across the surface of the head at
several different points and measure warpage by
inserting a feeler gauge between the straight edge and
the cylinder head surface. If warpage exceeds the
service limit, replace the cylinder head.

Cylinder Head Warp Limit:

.002” (.05 mm)

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CYLINDER HEAD DISASSEMBLY 2. Remove spring retainer and spring w.

CAUTION
Wear eye protection or a face shield during cylinder
head disassembly and reassembly.

NOTE
Keep all parts in order with respect to their location in
the cylinder head.
3
NOTE
Valves have inner and outer springs.

1. Using a valve spring compressor, compress the valve NOTE

springs and remove the split keeper q.
The valve springs should be positioned with the tightly
CAUTION wound coils against the cylinder head on progressively
wound springs e.
To prevent loss of tension, do not compress the valve
spring more than necessary.
3. Push valve out, keeping it in order for reassembly in
the same guide.
4. Measure free length of the inner and outer springs
with a Vernier caliper.

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5. Check spring for squareness. Replace spring if VALVE INSPECTION

measurements are out of specification.
1. Remove all carbon from valve with a soft wire wheel.
2. Check valve face for runout, pitting, and burned
spots. To check for bent valve stems, mount valve in
a drill or use “V” blocks and use a dial indicator.

6. Remove valve seals r.

NOTE
Replace seals whenever the cylinder head is
disassembled. Hardened, cracked or worn valve seals 3. Check end of valve stem for flaring, pitting, wear or
will cause excessive oil consumption and carbon damage q.
buildup.

4. Inspect split keeper groove for wear or flaring of the

keeper seat area w.

NOTE
The valves cannot be re-faced or end ground. Valves
must be replaced if worn, bent, or damaged.

5. Install the valve in its mating guide and lift it 5mm off
of the seat. Push valve back and forth and measure
deflection in two directions. If deflection exceeds limit
repeat test with a new valve, or measure stem to
guide clearance as outlined in Step 6 and 7 to
determine if wear is in the guide or the valve stem (or
both).

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NOTE
Be sure to measure each guide and valve combination
individually.

9. Replace valve and/or guide if clearance or deflection

is excessive.
NOTE
If valve guides are replaced, valve seats must be
reconditioned. Refer to Valve Seat Reconditioning for
procedure. 3

6. Measure diameter of valve stem with a micrometer in

three places and in two different directions (six
measurements total). Replace if excessive wear is
evident.

7. Measure valve guide e inside diameter at the top

middle and end of the guide using a small hole gauge
and a micrometer. Measure in two directions, front to
back and side to side.

8. Subtract valve stem measurement to obtain stem to

guide clearance.

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VALVE SEAT RECONDITIONING 1. Install pilot into valve guide e.

Valve Seat Inspection
Inspect valve seat in cylinder head for pitting, burnt
spots, roughness, and uneven surface. If any of the
above conditions exist, the valve seat must be
reconditioned. If the valve seat is cracked the cylinder
head must be replaced.

Cylinder Head Reconditioning

2. Apply cutting oil to valve seat and cutter.
IMPORTANT 3. Place 46° cutter on the pilot and make a light cut.
Servicing the valve guides and valve seats requires 4. Inspect the cut area of the seat.
special tools and a thorough knowledge of
reconditioning techniques.
• If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180°
and make another light cut.
CAUTION • If the cutter now contacts the uncut portion of the
Wear eye protection when performing cylinder head seat, check the pilot. Look for burrs, nicks, or
service. Valve guide replacement will require heating of runout. If the pilot is bent it must be replaced.
the cylinder head. Wear gloves to prevent burns. • If the contact area of the cutter is in the same
place, the valve guide is distorted from improper
installation and must be replaced. Be sure the
Follow the manufacturers instructions provided with the cylinder head is at the proper temperature and
valve cutting kit (commercially available). Abrasive stone replace the guide.
seat reconditioning equipment can also be used. Keep • If the contact area of the initial cut is greater than
valves in order with their respective seat. 75%, continue to cut the seat until all pits are
removed and a new seat surface is evident.
NOTE NOTE: Remove only the amount of material
Valve seat width and point of contact on the valve face necessary to repair the seat surface.
is very important for proper sealing. The valve must
contact the valve seat over the entire circumference of
the seat, and the seat must be the proper width all the
way around. If the seat is uneven, compression leakage
will result. If the seat is too wide, seat pressure is
reduced, causing carbon accumulation and possible
compression loss. If the seat is too narrow, heat
transfer from valve to seat is reduced and the valve
may overheat and warp, resulting in burned valves.

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5. To check the contact area of the seat on the valve 7. Remove valve and check where the Prussian Blue™
face, apply a thin coating of Prussian Blue™ paste to or black marker indicates seat contact on the valve
the valve seat. If using an interference angle (46°) face. The valve seat should contact the middle of the
apply black marker to the entire valve face q. valve face or slightly above, and must be the proper
width q.

6. Insert valve into guide and tap valve lightly into place
a few times.
• If the indicated seat contact is at the top edge of
the valve face and contacts the margin area w it
is too high on the valve face. Use the 30° cutter
to lower the valve seat.
• If too low use the 60° or 75° cutter to raise the
seat. When contact area is centered on the valve
face, measure seat width.
• If the seat is too wide or uneven, use both top
and bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45°
cutter and re-check contact point on the valve
face and seat width after each cut.

ITEM ANGLE
y 30º

u 45º or 46º

i 60º or 75º

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NOTE 13. Spray electrical contact cleaner into oil passages and
dry using compressed air.
When using an interference angle, the seat contact
point on the valve will be very narrow, and is a normal
condition. Look for an even and continuous contact
point on the black marker, all the way around the valve
face.

8. Clean all filings from the area with hot soapy water,
rinse, and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the
face of the valve. Lapping is not required with an
interference angle.
10. Insert the valve into its respective guide and lap using
a lapping tool or a section of fuel line connected to the
valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated,
and repeat process for the other valve.
12. Clean rocker assembly, cylinder head, valves, and
camshaft oil supply passages thoroughly.

ITEM DESCRIPTION
r Intake

t Exhaust

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CYLINDER HEAD ASSEMBLY NOTE

When all valves are installed, tap lightly with a flat
CAUTION punch on end of valve stem to seat split keepers. DO
Wear eye protection during assembly. NOT tap on top retainer or keepers may dislodge.

NOTE VALVE SEALING TEST

Assemble the valves one at a time to maintain proper 1. Clean and dry the combustion chamber area.
order.
2. Pour a small amount of clean solvent into each port
1. Install new valve seals on valve guides.
and check for leakage around each valve. The valve 3
seats should hold fluid with no seepage for at least
15 seconds.

2. Apply engine oil to valve guides and seats.

3. Coat valve stem with assembly lubricant or a mixture
of motor oil and molybdenum disulfide grease.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
5. Dip valve springs and retainer in clean engine oil and
install springs with closely spaced coils e toward the
cylinder head w.

6. Place retainer on springs and install spring

compressor. Compress spring only enough to allow
split keeper installation and prevent loss of spring
tension. Install split keepers with the gap even on
both sides. Repeat procedure for remaining valve

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CYLINDER REMOVAL CAM CHAIN TENSIONER BLADE

Follow engine disassembly procedures to remove
1. To remove the tensioner blade (C), remove PVT
cylinder head.
cover and drive clutch (refer to PVT Section).
1. Remove the two cylinder base bolts q. The hose NOTE
guide is attached to the lower base bolt.
Tensioner blade removal is only required for service of
the blade.

2. Remove bolt e securing tensioner blade to

crankcase.

2. Tap cylinder lightly with a plastic hammer in

reinforced areas only until loose.

3. Inspect blade for cracks, wear, or damage.

3. Rock cylinder forward and backward and lift it from

the crankcase.
4. Pull the lower chain guide w out of cylinder.
5. Inspect guide for cracks, wear, or damage.

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PISTON REMOVAL CYLINDER INSPECTION

1. Remove piston circlips and push piston pin out of 1. Remove all gasket material from the cylinder sealing
piston. If necessary, heat the crown of the piston surfaces. Refer to specifications at beginning of
slightly with a propane torch. chapter.
2. Inspect the top of the cylinder for warpage using a
CAUTION straight edge and feeler gauge.
Do not apply heat to the piston rings. The ring may lose
radial tension.

2. Remove the compression rings, starting with the top Cylinder Warp:
ring. .002” (.05 mm) MAX
• Using a piston ring pliers: Carefully expand ring
and lift it off the piston.
3. Inspect cylinder for wear, scratches, or damage.
CAUTION 4. Inspect cylinder for taper and out of round with a tele-
Do not expand the ring more than the amount scoping gauge or a dial bore gauge. Measure in two
necessary to remove it, or the ring may break. different directions, front to back and side to side, on
three different levels (1/2” down from top, in the mid-
• By hand: Placing both thumbs on end gap of ring dle, and 1/2” up from the bottom).
and expand the ring while lifting it off the piston.
Use care to not scratch the ring lands.
3. Repeat procedure for second ring.
4. The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. Remove top rail first followed by bottom rail
and expander.

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5. Record measurements. If cylinder is tapered or out of HONING TO DEGLAZE

round beyond specification, cylinder must be bored or A finished cylinder should have a cross-hatch pattern to
replaced. ensure piston ring seating and to aid in the retention of
Cylinder Taper Limit: the fuel/oil mixture during initial break in. Hone cylinder
according to hone manufacturer’s instructions, or these
.002” (.05 mm) Max.
guidelines:
Cylinder Out of Round Limit:
.002” (.05 mm) Max. • Use a motor speed of approximately 300-500 RPM,
run the hone in and out of the cylinder rapidly until
cutting tension decreases. Remember to keep the
hone drive shaft centered (or cylinder centered on
CYLINDER HONING PROCEDURE arbor) and to bring the stones approximately 1/2” (1.3
cm) above and below the bore at the end of each
CAUTION stroke.
A hone which will straighten as well as remove material • Release the hone at regular intervals and inspect the
from the cylinder is very important. Using a common bore to determine if it has been sufficiently deglazed,
spring loaded glaze breaker for honing is not advised. and to check for correct cross-hatch.
Polaris recommends using a rigid hone or arbor honing CAUTION
machine.
Do not allow cylinder to heat up during honing.
Cylinders may be wet or dry honed depending upon the
hone manufacturer’s recommendations. Wet honing After honing has been completed, inspect cylinder for
removes more material faster and leaves a more distinct thinning or peeling.
pattern in the bore.
IMPORTANT
Clean the Cylinder After Honing

It is very important that the cylinder be thoroughly

cleaned after honing to remove all grit material. Wash the
cylinder in a solvent, then in hot, soapy water. Use
electrical contact cleaner if necessary to clean these
areas. Rinse thoroughly, dry with compressed air, and oil
the bore immediately with Polaris 4 Cycle Lubricant to
prevent the formation of surface rust.
If cylinder wear or damage is excessive, it will be
necessary to replace the cylinder. Hone only enough to
deglaze the outer layer of the cylinder bore.

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PISTON INSPECTION 4. Measure piston pin O.D. Replace piston pin if out-of-
round.
NOTE
refer to specifications at the beginning of this chapter as
required.

1. Measure piston outside diameter at a point 7 mm up

from the bottom of the piston at a right angle to the
direction of the piston pin.

5. Measure connecting rod small end ID. Replace

crankshaft if out-of-round.

ITEM DESCRIPTION
q Piston

w Piston Pin

e 7 mm measurement

2. Subtract this measurement from the maximum

cylinder measurement obtained earlier.
Piston to Cylinder Clearance
Std: .0004- .0014” (0.01- 0.04 mm)
Limit: .0039” (.1 mm)

3. Measure piston pin bore. Replace piston if out-of-

round.

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6. Measure piston ring to groove clearance by placing PISTON RING INSTALLED GAP
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to- 1. Place each piston ring q inside cylinder w using
groove clearance exceeds service limits. piston to push ring squarely into place as shown.

Piston Ring Installed Gap

See:Engine Service Data, page
ITEM DESCRIPTION
q Piston 2. Measure the gap with a feeler gauge e at both the
top and bottom of the cylinder.
w Ring
NOTE
e Feeler Gauge
Measure at two points in the cylinder r. A difference in
end gap indicates cylinder wear. The cylinder should be
measured for excessive taper and out of round.

3. If the installed gap measurement exceeds the limit,

replace the rings.

NOTE
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings. A re-bored
cylinder should always be scrubbed thoroughly with hot
soapy water, rinsed, and dried completely. Wipe
cylinder bore with an oil rag immediately to remove
residue and prevent rust.

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BOTTOM-END DISASSEMBLY
FLYWHEEL REMOVAL / INSPECTION STATOR REMOVAL
Remove the flywheel cover, the flywheel nut, and
1. Remove flywheel.
washer. Install flywheel puller and remove flywheel.
2. Loosen stator screws q and pulse coil screws w
CAUTION evenly and remove stator. Note wire routing for
assembly.
Do not hammer or strike the tool or crankshaft may be
damaged.

PA-45153
Flywheel Puller

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OIL PUMP REMOVAL 4. Remove body screw and plate.

NOTE
Oil pump is not a serviceable assembly.

NOTE
The CVT system, starter motor, starter drive, flywheel,
stator, oil pump and transmission can be serviced with
the engine in the frame.

1. Remove stator.
2. Remove oil pump body screws e.

5. Inspect gears and drive pins r on pump shaft for

wear or damage. Replace pump assembly if parts are
worn, scratched or otherwise damaged.
6. If parts pass inspection, clean and lubricate the pump
parts with clean engine oil.
7. Assemble pump and tighten screw securely.
8. Turn pump gear by hand to check for smooth
operation. Replace pump or re-clean parts if any
roughness or binding is evident.

3. Remove oil pump assembly. Inspect surface of

crankcase for scratches or wear. Replace crankcase
if damaged or deeply grooved.

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CRANKCASE DISASSEMBLY CRANKSHAFT REMOVAL

NOTE 1. Support the crankcase in the upright position as
shown.
Engine must be removed to perform crankcase or
crankshaft service. 2. Lift cam chain and move it as required to disengage
the chain from the crankshaft sprocket teeth.
The CVT system, starter motor, starter drive, flywheel, 3. Remove crankshaft.
stator, oil pump and transmission can be serviced with
the engine in the frame.

CAUTION
3
Use care during the crankshaft removal process to
avoid damage to the cam chain.

1. Remove engine, cylinder, piston, and stator

assembly.
2. Loosen crankcase screws (circled) evenly and
remove.

3. Separate right crankcase from left by tapping gently

with a soft face hammer evenly around the case as
required. Leave the crankshaft in the left crankcase
half. Do not attempt to remove crankshaft with right
case or cam chain will be damaged.

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CRANKSHAFT / CAM CHAIN / SPROCKET 5. Remove cam chain. Inspect chain for worn or missing
INSPECTION rollers or damage. Replace if worn excessively or as
part of any crankshaft repair.
1. Inspect the crankshaft main bearings and cam chain
sprocket for wear or damage.

IMPORTANT
Due to extremely close tolerances and minimal wear,
the bearings must be inspected visually, and by feel.
Look for signs of discoloration, scoring or galling. Turn
outer race of each bearing. Bearings should turn
smoothly and quietly. The inner race of each bearing
should fit tightly on the crankshaft. The outer race
should be firm with minimal side to side movement and
no detectable up and down movement.

2. The connecting rod big end bearing is a roller NOTE

bearing. Visually inspect connecting rod big end for Install new cam chain as a part of crankshaft repair.
scoring, damage or excessive wear. If connecting rod
passes visual inspection, measure radial clearance
carefully with crankshaft clamped in V-blocks at
points q and a dial indicator measuring total up and CRANKCASE OIL STRAINER INSPECTION
down movement w. Compare to specifications. If 1. Remove strainer plug.
clearance is excessive replace the crankshaft
assembly.

3. Clean crankshaft and all oil passages in crankcase

and crankshaft.
4. Be sure oil collector passage on right side crankshaft
2. Remove oil strainer and visually inspect for any rips,
counterweight is clear. This passage collects oil
tears or obstructions in screen.
supplied by the right side crankcase oil passage (from
the oil pump) and moves it by centrifugal force to the 3. Replace oil strainer if it fails visual inspection.
connecting rod big end bearing. See “Oil Flow
Diagram”, page 3.11

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ENGINE ASSEMBLY
CRANKCASE ASSEMBLY PISTON RING INSTALLATION
Lubricate all bearings with clean engine oil before
assembly. IMPORTANT
Apply clean engine oil to all ring surfaces and ring
1. Support left side crankcase upright.
lands. Always check piston ring installed gap before
2. Drop cam chain into position in the cam chain area rings are installed on piston. If the piston has been in
and hold. service, clean any accumulated carbon from the ring
3. Install crankshaft. Be sure camshaft chain is engaged grooves and oil control ring holes.
on lower drive sprocket.
3
1. Oil Control Ring: Place the oil control ring expander
in oil ring groove with the end gap facing forward. The
expander has no up or down marking and can be
installed either way. The ends should butt squarely
together and must not overlap.
2. Install the oil ring top rail with the end gap at least 30°
from the end of the expander.
3. Install the bottom rail with the gap at least 30° from
the end of the expander on the side opposite the top
rail gap.
4. Second Ring: Install the second ring with the mark
facing up (if applicable). Position the end gap toward
the rear (intake) side of the piston.
5. Top Ring: Install the top ring with the chamfered
4. Clean mating surfaces of crankcases and install edge facing up (if applicable).
alignment pins and a new gasket. 6. Check to make sure the rings rotate freely in the
5. Install case screws. Torque in two steps to groove when compressed by hand. Verify that the
specification following sequence shown. ring gaps are 120 degrees apart from each other
before installation.

TORQUE
Crankcase Screws:
87 in-lbs (10 Nm)

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PISTON INSTALLATION TENSIONER BLADE INSTALLATION

Install tensioner blade and tighten mounting bolt to
CAUTION specified torque (arrow).
Do not re-use circlips. Circlips become deformed during
the removal process. Do not compress the new clip
more than necessary to prevent loss of radial tension.
Severe engine damage may result if circlips are re-used
or deformed during installation.

1. Install a new circlip on one side of the piston with the

end gap facing up or down.
2. Apply clean engine oil to the piston rings, ring lands,
piston pin bore, piston pin, and piston skirt. Lubricate
the connecting rod (both ends) and crankshaft main
bearing area.

IMPORTANT
Install the piston on the connecting rod with the “IN”
casting mark q facing the intake side of engine. The
piston pin should be a push fit into the piston. TORQUE
Tensioner Blade Mounting Bolt:
104 in-lbs (12 Nm)

3. Install the other circlip. Push piston pin in both

directions to make sure clips are properly seated in
the grooves.
4. Place dowel pins in crankcase and install a new
cylinder base gasket.
5. Lubricate piston and rings with engine oil. Verify that
the ring gaps are 120° apart from each other before
installation.

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CYLINDER INSTALLATION
NOTE
Clean gasket surfaces on crankcase and cylinder
thoroughly.

1. Install the dowel pin(s). Install a new base gasket

2. Apply engine oil liberally to cylinder bore and tapered
area at bottom of cylinder. Place cylinder onto
cylinder studs.
3
3. Guide cam chain through cylinder and secure with
wire.
4. Install a ring compressor or compress rings with
fingers and guide piston into taper at bottom of
cylinder.
5. When rings are past the tapered portion of cylinder,
install cylinder until seated against base gasket.

6. Install cam chain guide. Pull cam chain tight so blade

will slide into notch in crankcase.

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CYLINDER HEAD & CAMSHAFT 3. Install cam chain sprocket to chain with dot on
INSTALLATION sprocket at the top. Sprocket must be timed before
cylinder head is installed.
NOTE
Clean gasket surfaces on cylinder head and cylinder to
remove all traces of old gasket material.

1. Install two dowel pin (s) and a new cylinder head

gasket.

4. Slide the head onto studs and guide the sprocket with
chain through the cylinder head chain tower.

2. Rotate engine to Top Dead Center.Finding Top Dead

Center (TDC), page

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5. Install cam chain sprocket onto camshaft. Be sure dot 9. Torque cylinder head and bolts in two steps to
q on sprocket is aligned with mark w on cylinder specification, following the sequence shown.
head. Turn camshaft to align holes and install
sprocket bolts. Torque bolts to specification.

TORQUE
Camshaft Sprocket Bolt:
69 in-lbs (8 Nm)

6. Install two cylinder base bolts e

7. Install cylinder head bolt r.
8. Install four head nuts t with new sealing washers.

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CAM CHAIN TENSIONER INSTALLATION 4. Install spring and cap with new sealing washer.
Torque cap to specification. Verify proper camshaft
1. Install tensioner body with a new gasket onto the timing (Step 5).
cylinder.
2. Depress ratchet pawl q and push plunger w into
tensioner body.

TORQUE
3. With the plunger retracted, install the tensioner Cam Chain Guide Bolt:
assembly and tighten the bolts to specification. 69 in-lbs (8 Nm)

5. Slowly rotate engine 2-3 revolutions in normal

direction of rotation. Rotate to TDC on compression
stroke and verify camshaft timing is correct.

TORQUE
Cam Chain Tensioner Bolts:
87 in-lbs (10 Nm)

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6. If piston rings have been replaced, drain engine oil

and replace with Polaris Performance (PS-4)
Synthetic Extreme Duty oil for the first 10 hours of
operation. See “Engine Lubrication”, page 3.15

IMPORTANT
See Valve Clearance Adjustment, page to complete
engine assembly.

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EXHAUST 2. Discard heat shield gaskets.

SPARK ARRESTOR REPLACEMENT

1. Remove three fasteners.

2. Remove spark arrestor from muffler.

3. Remove Gasket with gasket scraper and discard.
4. Install new gasket.
5. Clean spark arrestor.
6. Install spark arrestor and fasteners.
7. Torque fasteners to specification.

HEAT SHIELD REPLACEMENT

1. Remove two 10mm fasteners and washers. Remove
heat shield.

3. Replace gasket.
4. Install heat shield and fasteners.
5. Torque to specification.

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TRANSMISSION
TRANSMISSION DISASSEMBLY AND 5. Remove the cover screws.
INSPECTION
NOTE
Engine removal is not required to service transmission
components. Process shown below is with engine
removed for clarity. The basic disassembly and
inspection process is similar for all models. Differences
are noted as required.
3
1. Drain the transmission oil from the gear case q and
engine oil from crankcase w.

6. Remove cover with output shaft. Push or tap on shift

shaft to keep it in the case.
7. Remove gasket and discard.

2. Remove oil dipstick tube e.

3. Remove sprocket cover r and drive sprocket.
4. Mark shift selector shaft t and shift lever arm so the
arm can be reinstalled in the same location. Remove
arm and bracket.

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8. Note timing of shift shaft before removing. The center 10. Remove shift fork shaft i.
tooth y on shift shaft is positioned between the two
dots on the drum teeth.

11. Remove main shaft and shift fork as an assembly.

9. Remove the shift shaft by pulling straight outward. 12. Remove the counter shaft.
DO NOT LOSE the spring and plunger u on the inner
end of the shaft. This plunger contacts the gear
position switch.

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13. Remove shift drum. Push detent ball located at o 15. Loosen the bolt and remove the shift detent ball and
back against spring pressure to ease removal. spring assembly.

14. If input shaft or gear a requires service, remove

driven clutch as outlined in CVT Chapter.

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TRANSMISSION SHIFTER GEAR 4. Inspect the shift fork q for scoring or signs of wear.
Area w should not show contact.
CAUTION
Always wear the appropriate protective gear and use
caution when operating a press.

1. With transmission components removed, inspect all

shaft bearings visually and by feel. Bearings should
roll smoothly, without excessive movement or noise.
Replace any bearing that is removed, as the removal
process destroys the bearing.
2. Bearings can be removed using a standard blind
bearing remover. Apply lithium grease to outer race of
new bearings and press into cover or case by the
outer race. Do not press on inner race or bearing will
be damaged.
3. Press output shaft out of cover with an arbor press or
a hydraulic press from outside to inside, while
5. Inspect sliding gear dogs and dog slots in the mating
supporting cover completely.
gears e for wear or damage. The edges of dogs and
slots should be square and not rounded. Replace
both sliding gear and mating gears if any edges are
rounded or chipped.

NOTE
Inspect all shafts for wear in the bearing contact areas.
The sealed output shaft bearing (in the transmission
cover) has a snap ring that must be removed before
output shaft bearing can be pressed out of the cover.

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6. Substantial axial movement in the forward drive gear 10. Remove the snap ring and thrust washer to access
is due to liberal oil clearance for the bushing, and is a the reverse gear (110cc models).
normal condition. Gear replacement is not required
due to axial movement if radial movement (shown in
Step 6) passes inspection.

ITEM DESCRIPTION NOTES

7. Radial movement should not exceed .0015 in. (.04
mm). r Collar, Shaft pressed
onto shaft
t Washer —

y Asm, Gear Support

gear on
edges to
press shaft
out
u Ratchet, Shift —

i Snap Ring —

o Washer —

a Asm, Reverse Gear —

s Shaft, Transmission —
Shaft Disassembly
Shaft Assembly
8. If radial movement in Step 7 was excessive, support
the forward gear and press the shaft through the 11. Assemble the reverse gear (110cc), washer, a new
spacer to disassemble it from the shaft. snap ring, and the sliding gear on the shaft.
9. Remove the sliding gear from the shaft.

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12. Replace gear and place it on the shaft, followed by

the washer d as shown.

13. Grooves f on spacer face the washer. Press spacer

onto shaft until firmly seated against the step on the
shaft.

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TRANSMISSION ASSEMBLY

ITEM DESCRIPTION TORQUE

q Cover Bolts 87 in-lbs (10 Nm)

w Detent Bolt 25 ft-lbs (34 Nm)

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NOTE 2. Check transmission operation before final assembly,

and after installing outer cover and output shaft.
To reassemble the transmission, reverse the
disassembly procedure, refer to exploded view, and FORWARD
review the following information and special notes.

1. Use caution when installing the gear position

indicator spring q and pin w located in the end of the
shift shaft. Removal of the indicator switch (located
under the clutch cover) is recommended.

NEUTRAL

REVERSE

3. Assemble the detent ball and spring with

transmission lubricant. Tighten bolt to specification.

TORQUE
Shift Detent Hex Bolt:
25 ft-lbs (34 Nm)

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4. Install the transmission cover and new gasket. Install

the eight retaining bolts and torque in two steps to
specification following the sequence shown.

TORQUE
Transmission Cover Bolt:
87 in-lbs (10 Nm)

5. Install drive sprocket. Torque retainer plate screws to

specification.
6. Install oil drain plug with a new sealing washer and
torque to specification.

TORQUE
Drive Sprocket Retainer Bolt:
87 in-lbs (10 Nm)
Transmission Drain / Fill Plugs:
14 ft-lbs (19 Nm)

7. Fill transmission with lubricant as specified

inTransmission Lubrication, page 2.23.

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STARTER DRIVE MECHANISM (ELECTRIC) 4. Remove idler gear from shaft.

1. Remove CVT cover. See Clutch Cover Removal,

page .
2. Remove drive clutch.

5. Remove thrust washer from shaft.

3. Remove idler gear retainer plate.

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6. Before removing the starter one-way clutch / gear 8. Lift the gear off of the one-way clutch. Note the
assembly, inspect the gear operation. The ring gear washer inside the hub e. This washer must be
should rotate smoothly and freely in a clockwise centered upon assembly.
direction q. The gear should lock and turn the
crankshaft when rotated in a counterclockwise
direction w.

9. Inspect the surface of the gear hub r. It must be

smooth and free of surface damage. Be sure bearing
in hub turns smoothly.
7. Hold the gear and the one-way clutch together to
prevent rollers from falling out of the clutch. Remove
the one-way clutch and drive gear as an assembly.

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10. Remove the rollers, plungers and springs t. Replace 13. Be sure the washer is centered and hub is fully
assembly if damaged or worn. Inspect the splines y seated in the one way clutch. Hold the parts together
on the one-way clutch for wear or damage. and assemble to crankshaft.

14. Install idler gear washer on shaft and idler gear.

Install retaining plate. Re-assemble CVT system
11. Assemble the springs, plungers, and rollers into the
hub. Push each roller u back toward plunger and (Chapter 7)
spring, and then release. Rollers should return freely
to the extended position and stop against the hub.

TORQUE
12. Place the washer in the one way clutch. Install the
gear hub into the clutch with a counterclockwise Starter Idler Gear Plate:
rotating motion. 87 in-lbs (10 Nm)

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KICK START
KICK START DISASSEMBLY / INSPECTION 3. Disconnect hooked end of spring and set against stop
at w.
CAUTION
The kick start spring is under tension. Wear eye
protection during disassembly and assembly of the kick
start mechanism.

NOTE
It is not necessary to remove the kick start lever or kick
3
drive components to remove the engine cover.

4. Mark the shaft at the opening of the kick start pedal

e, or note position of kick start pedal before
removing.

1. Remove clutch cover and cover gasket.Clutch Cover

Removal, page 7.5
2. Remove the kick pinion q with drag spring attached
by rotating the kick start pedal.

5. Remove retaining ring r and backing washer from

the shaft.

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6. Lift hooked end of spring over the stop and allow it to 2. Install spring in cover with hook and tab ends facing
unwind completely (about another 180 degrees). up.
3. Lubricate kick shaft bushing q with grease and install
on shaft followed by a new O-ring w.

7. Remove shaft with bushing t, O-ring y, and spring.

4. Install shaft with bushing and O-ring into cover.

5. Position hooked end e against stop, and engage
straight end r on edge of gear as shown.

8. Inspect shaft, bushing, and spring for wear or

damage. Check shaft pivot boss for cracks.

KICK START ASSEMBLY

1. Secure cover lightly in a vise as shown. Protect the
surface of the cover from damage.

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6. Hold spring up against kick gear and rotate gear 9. Install kick start pedal, aligning marks made
counterclockwise until trailing edge t is past the stop previously.
y. Push gear down until seated and then release
gear to rest against the stop.

NOTE
It may be necessary to center the spring on the hub in
order to allow shaft to fully seat in the cover.

TORQUE
Kick Start Bolt:
87 in-lbs (10 Nm)

10. Install drag spring on kick gear with bend toward

bevel gear.
7. Hold shaft in place so spring does not disengage, and
turn cover over.
8. Install retaining ring on shaft.

11. Wind the hook end of the spring over the post u.

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12. Install kick pinion with tab of drag spring i engaged

in the between the posts o.

13. Install cover. Clutch Cover Installation, page 7.6.

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TROUBLESHOOTING
SPARK PLUG FOULING ENGINE (GENERAL)
Engine Turns Over But Fails to Start
• Spark plug cap loose or faulty
• Choke cable adjustment, cable or shaft sticking • No fuel
• Incorrect spark plug heat range or gap • Dirt in fuel line or filter
• Carburetor inlet needle and seat worn • Fuel will not pass through fuel valve
• Jet needle and / or needle jet worn or improperly • Fuel pump inoperative / restricted
adjusted • Tank vent plugged
• Loose jets in carburetor or calibration incorrect for
altitude/temperature
•
•
Engine flooded with fuel
Low compression (high cylinder leakage)
3
• Incorrect float level setting • No spark (Spark plug fouled)
• CVT system calibrated incorrectly or components
worn or mis-adjusted
• Fuel quality poor (old) Engine Does Not Turn Over
• Low compression
• Restricted exhaust • Discharged battery
• Weak ignition (loose coil ground, faulty coil, stator, or • Loose or corroded battery terminals / cables
TRS switch) • Starter motor electrical circuit faulty
• TRS switch mis-adjusted • Engine seized or mechanical failure
• Restricted air filter (main or pre-cleaner) or breather • Kickstart components damaged
system
• Improperly assembled air intake system
• Restricted engine breather system Engine Runs But Will Not Idle
• Oil contaminated with fuel
• Restricted crankcase vent (engine breather) • Carburetor pilot (idle) circuit restricted or blocked
• Carburetor misadjusted
• Choke not adjusted properly
• Low compression
• Insufficient valve clearance (too tight)
• Crankcase breather restricted
• Air filter restriction
• Old (degraded) fuel
• Incorrect ignition timing / sheared flywheel key

Engine Idles But RPM Will Not Increase

• Spark plug fouled/weak spark

• Broken throttle cable
• Obstruction in air intake
• Air box removed (reinstall all intake components)
• Incorrect or restricted carburetor jetting
• TRS switch limiting speed
• Reverse speed limiter limiting speed
• Carburetor vacuum slide sticking/diaphragm
damaged
• Incorrect ignition timing / sheared flywheel key
• Restricted exhaust system
• Cam lobe worn

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Engine Has Low Power Transmission

Gear Will Not Engage
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage • Shift arm indexed incorrectly (hits bracket)
(check compression / cylinder leakage) • Shift arm slipping on spline
• CVT not operating properly • CVT Belt broken
• Restricted exhaust muffler • Internal trans gear damage
• Dirty / restricted carburetor • Shift fork broken or bent
• Cam lobe worn • Shift shaft broken

Piston Failure - Scoring Pops Out Of Gear

• Lack of lubrication • Shift arm indexed incorrectly (hits bracket before full
• Dirt entering engine through cracks in air filter or engagement)
ducts • Shift arm slipping on spline
• Engine oil dirty or contaminated • Detent spring or ball missing, worn, or broken
• Gear engagement dogs worn (rounded) or broken
• Shift fork bent
Excessive Smoke and Carbon Buildup

• Excessive piston-to-cylinder clearance Noise

• Worn rings, piston, or cylinder
• Worn valves, guides or seals • Incorrect transmission lubricant
• Restricted crankcase vent • Lubricant level too low
• Air filter dirty or contaminated • Lubricant level too high
• Engine oil level too high • Bearings worn or damaged
• Gears worn or damaged
• CVT problem (belt)
Low Compression • Final drive (chain or sprockets) worn or damaged

• Cylinder head gasket leak

• No valve clearance or incorrectly adjusted
• Cylinder or piston worn
• Piston rings worn, leaking, broken, or sticking
• Bent valve or stuck valve
• Valve spring broken or weak
• Valve not seating properly (bent or carbon
accumulated on valve area)
• Rocker arm sticking

Backfiring

• TRS or speed limiter system malfunction

• Fouled spark plug or incorrect plug or plug gap
• Carburetion faulty - lean condition
• Intake / Exhaust system air leaks
• Spark plug cap cracked / broken
• Ignition coil faulty
• Ignition or kill switch circuit faulty
• Ignition timing incorrect
• Sheared flywheel key
• Poor connections in ignition system wiring
• Ignition system wiring wet
• Cam lobe worn or valve sticking
• Lean condition

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CHAPTER 4
FUEL SYSTEM
CARBURETION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
CARBURETOR FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
CARBURETOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
FLOAT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
PILOT JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 4
AIR / FUEL MIXTURE RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
JET NEEDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
NEEDLE JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
THROTTLE OPENING VS. FUEL FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
THROTTLE SLIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
MAIN JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
PILOT SYSTEM (IDLE - 3/8 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
SLIDE CUTAWAY (1/8 - 3/8 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
JET NEEDLE/NEEDLE JET (3/8 - 3/4 THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
MAIN SYSTEM (3/4 TO FULL THROTTLE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
FUEL DELIVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
CARBURETOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
CARBURETOR FLOAT BOWL DRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
CARBURETOR REMOVAL - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
CARBURETOR DISASSEMBLY - 50CC (MIKUNI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
CARBURETOR DISASSEMBLY - 90CC (KEIHIN/SUNWORLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.12
CARBURETOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
CARBURETOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.14
FLOAT HEIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
CARBURETOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
NEEDLE AND SEAT LEAK TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
FUEL TANK EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
FUEL VALVE LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
FUEL VALVE SERVICEOUTLAW 50 / OUTLAW 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
FUEL VALVE LAYOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
AIR CLEANER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
POOR IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21

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FUEL SYSTEM

CARBURETION SYSTEM
SPECIAL TOOLS CARBURETION SPECIFICATIONS
PART NUMBER TOOL DESCRIPTION OUTLAW 50
MityVac® Cutaway N/A
2870975
Pressure Test Tool
Pilot Air Screw 2.5 turns out
Carburetor Float
2872314 Adjustment Tool Needle & Seat 1.2

Carburetor Adjuster Pilot Jet 15

PA-47361 “D Shaped” Main Jet 62.5

Bosch Automotive Service Solutions: 1-800-328-6657 E-clip Position #4 From Top

or http://polaris.service-solutions.com/
OUTLAW 90 / SPORTSMAN 90
WARNING
Cutaway 3.0
• Gasoline is highly flammable and explosive under
certain conditions. Pilot Air Screw 1.75 ± .5 turns out
• Always exercise extreme caution whenever handling
Jet Needle 89Q-3
gasoline.
• Always refuel outdoors or in a well-ventilated area. Pilot Jet 40
• Always turn off the engine before refueling.
Main Jet 80
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or E-clip Position #3 From Top
near the area where refueling is performed or where
gasoline is stored.
• If gasoline spills on your skin or clothing, immediately
wash it off with soap and water and change clothing.
• Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can cause
loss of consciousness or death in a short time.
• Never drain the fuel system when the engine is hot.
Severe burns may result.

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 FUEL SYSTEM

CARBURETOR FUNCTION
CARBURETOR COMPONENT FUNCTION
MAIN
MAIN MAIN
SYSTEM COMPO-
FUNCTION AFFECT
NENTS
Maintains
Float Inlet Pipe, specified fuel All
System Needle and level in float systems;
(Level Seat, Float chamber all throttle
Control) and Float Pin (carburetor ranges
float bowl).
Supplies All
Passages in
atmospheric
Venting carburetor
and vent
pressure to
systems;
all throttle
4
float ranges.
lines.
chamber.
All
Provides a
throttle
richer fuel /
Choke Lever, ranges.
Starter air mixture to
Cable, and Greatest
(Choke the
Choke effect at
Plate) combustion
Butterfly low
chamber
throttle
during cold
settings
starts.
and idle.
Pilot Jet /
Passage-
ways, Pilot– Mainly
Mixture Primarily idle to
Pilot Screw with supplies fuel 1/4
(Idle Spring at idle and throttle.
System) Washer and low throttle Minimal
Sealing O– positions. effect
Ring, Pilot after 1/2
Outlet and throttle.
Throttle
Valve.
Main Jet,
Main Air Supplies fuel
Passage, at mid–range
Main 1/4 to full
Needle Jet, and high
System throttle.
Jet Needle, throttle
Throttle settings.
Valve.

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FUEL SYSTEM

CARBURETOR OPERATION
OPERATION OVERVIEW FLOAT SYSTEM
The engine of a vehicle is operated under a wide range The float system is designed to maintain a constant
of conditions, from idling with the throttle valve remaining height of gasoline during operation. When the fuel
almost closed, to full load or maximum output with the flowing from the fuel pump into the float chamber through
throttle valve fully opened. In order to meet the the needle valve reaches the constant fuel level, the
requirements for the proper mixture ratio under these floats rise. When the buoyancy of the float and the fuel
varying conditions, a low speed fuel system, or pilot pressure of the fuel pump balance, the needle valve
system, and a main fuel system are provided in these seals the orifice in the needle seat, preventing further
type of carburetors. fuel delivery, and the level of fuel in the bowl remains
relatively constant.
The function of a carburetor is to produce a combustible
air/fuel mixture by breaking fuel into tiny particles in the The fuel level in the bowl assists in controlling the
form of vapor, to mix the fuel with air in a proper ratio, amount of fuel in the fuel mixture. Too high a level allows
and to deliver the mixture to the engine. A proper ratio more fuel than necessary to leave the nozzle, enriching
means an ideal air/fuel mixture which can burn without the mixture. Too low a level results in a leaner mixture,
leaving an excess of fuel or air. Whether the proper since not enough fuel leaves the nozzle. Therefore, the
mixture ratio is maintained or not is the key to efficient predetermined fuel level should not be changed
engine operation. arbitrarily.
This carburetor has varying operations depending upon
varying driving conditions. It is constructed of a float
system, pilot system, main system, and starter system or
initial starting device.

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 FUEL SYSTEM

PILOT JET
From idling to low speeds, the fuel supply is metered by proper air/fuel mixture ratio at the medium throttle valve
the pilot jet. There are several air bleed openings in the opening (between 1/4 and 3/4 opening).
sides of the pilot jet which reduce the fuel to mist. The
Having the proper needle jet and jet needle has a major
number stamped on the jet is an indication of the amount
impact on engine performance at partial load. The jet
of fuel in cc’s which passes through the jet during a one
needle tapers off at one end and the clearance between
minute interval under a given set of conditions. the jet needle and the needle jet increases as the throttle
valve opening gets wider. The air/fuel mixture ratio is
controlled by the height of the “E” clip inserted into one of
the five slots provided in the head of the jet needle. The
previous chart shows the variation of fuel flow based on
the height of the “E” clip.

JET NEEDLE
The jet needle has five adjustment grooves cut into the
upper portion, and is tapered from approximately the
4
middle of the needle to the lower end. The top is fixed to
the center of the throttle valve by the needle clip, and the
tapered end extends into the needle jet. Fuel flows
through the space between the needle jet and jet needle.
This space does not vary until the throttle reaches the 1/4
open point. At that time the tapered portion of the needle
begins to move out of the jet, affecting fuel flow as the
opening enlarges. If the needle clip is changed from the
standard position to a lower groove, the needle taper
AIR / FUEL MIXTURE RATIO starts coming out of the jet sooner, resulting in a richer
mixture. Moving the clip higher produces a leaner
mixture. If the taper is worn due to vibration, fuel flow
may be significantly affected.

A carburetor with a slide type throttle valve is also called

a variable venturi type carburetor. In this type of
carburetor, the needle jet and jet needle serve to control

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FUEL SYSTEM

NEEDLE JET THROTTLE SLIDE

The needle jet works in conjunction with the jet needle to The throttle slide controls the rate of engine air intake by
regulate fuel flow rate. An air bleed opening in the side of moving up and down inside the main bore. At small
the needle jet brings in air measured by the air jet. This throttle openings, air flow control is performed chiefly by
air initiates the mixing and atomizing process inside the the cutaway. By controlling air flow the negative pressure
needle jet. over the needle jet is regulated, in turn varying the fuel
flow.

THROTTLE OPENING VS. FUEL FLOW

In a full throttle condition the cross sectioned area
between the jet needle and the needle jet is larger than
Throttle valves are numbered 1.0, 1.5, 2.0, etc.,
the cross sectioned area of the main jet. The main jet
according to the size of the cutaway. The higher the
therefore has greater control over fuel flow.
number, the leaner the gasoline/air mixture.

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 FUEL SYSTEM

MAIN JET PILOT SYSTEM (IDLE - 3/8 THROTTLE)

When the throttle opening becomes greater and the area The pilot system’s main function is to meter fuel at idle
between the needle jet and jet needle increases, fuel and low speed driving. Though its main function is to
flow is metered by the main jet. The number on the jet supply fuel at low speed, it does feed fuel continuously
indicates the amount of fuel CCs which will pass through throughout the entire operating range.
it in one minute under controlled conditions. Larger
Fuel for the pilot jet is drawn from the float bowl, mixed
numbers give a greater flow, resulting in a richer mixture. with air regulated by the air screw, and delivered to the
engine through the pilot outlet.
The mixture is regulated to some degree by adjusting the
air screw. When the air screw is closed, the fuel mixture
is made richer as the amount of air is reduced. When the
air screw is opened, the mixture is made more lean as
the amount of air is increased.

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FUEL SYSTEM

SLIDE CUTAWAY (1/8 - 3/8 THROTTLE) JET NEEDLE/NEEDLE JET (3/8 - 3/4
Throttle valve cutaway effect is most noticeable at 1/4 THROTTLE)
throttle opening. The amount of cutaway is pre- The jet needle and needle jet have the most effect
determined for a given engine to maintain a 14:1 air/fuel between 3/8 and 3/4 throttle opening. Some mixture
ratio at part throttle. A steep angle would indicate a fairly adjustment can be accomplished by changing the
lean mixture because there is less resistance to air flow. location of the “E” clip on the needle. Moving the clip
A flat angle would provide a much richer mixture down raises the needle in the jet passage and richens
because there is more resistance to air flow. the mixture. Moving the clip up lowers the needle in the
The venturi shape can be adjusted for each engine’s jet passage and leans the mixture. Letter and number
breathing characteristics by using a different valve codes are stamped into the needle and the jet indicating
cutaway angle. A number will be stamped into the bottom sizes and tapers of each.
of the valve (e.g. 2.5) indicating the size of the cutaway.
The higher the number, the steeper the angle.

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 FUEL SYSTEM

MAIN SYSTEM (3/4 TO FULL THROTTLE) FUEL DELIVERY

The main system is designed for delivering fuel between The throttle opening chart below demonstrates
low speed and high speed operation. This system is component relationship to fuel flow versus throttle valve
made up of the jet needle, needle jet, and main jet. The opening.
main system begins to take effect as soon as there is
The pilot system’s main function is that of a low speed
enough air flow into the carburetor venturi to draw fuel up
jet. Its most effective range of fuel delivery is from idle to
through the main jet and needle jet assembly. This approximately 3/8 throttle valve opening.
system works in conjunction with the needle jet system.
The throttle slide controls the rate of engine air by its
During low speed driving, there is very little clearance movement up and down in the carburetor venturi. At
between the jet needle and the needle jet; therefore, very small throttle openings the air flow is regulated chiefly by
little fuel from the main jet can pass between the jet the valve cutaway, with greatest effectiveness at 1/4
needle and the needle jet. As the throttle valve opening throttle opening. Throttle valves are numbered 1.0, 1.5,
is increased, the tapered jet needle is raised farther out 2.0, etc., according to the size of the cutaway.
of the needle jet, allowing greater fuel flow. Under full Decreasing the cutaway number will increase the
throttle opening, the cross sectioned area of clearance amount of fuel delivered in its effective range.
between the jet needle and the needle jet becomes
The jet needle and needle jet have an effective operating
4
greater than the cross sectioned area of the main jet.
range from approximately 1/8 to 7/8 throttle opening. The
Thus the main jet is now controlling the amount of fuel
amount of fuel delivered during this range relies upon the
flow.
jet needle clip position, as well as the needle jet size and
other specifications.
The main jet affects fuel delivery at 1/4 throttle and
consistently increases to full throttle opening.

VENT SYSTEM
The fuel tank vent supplies atmospheric pressure to the
fuel in the tank. The vent must be free of debris and
restrictions to prevent lean mixture and possible engine
damage. All vent lines must be properly routed to prevent
damage to the line and to prevent contaminants from
entering the tank.

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FUEL SYSTEM

CARBURETOR SERVICE
CARBURETOR FLOAT BOWL DRAINING CARBURETOR REMOVAL - GENERAL
The carburetor float bowl should be drained periodically The following procedure is provided to use as a
to remove moisture or sediment from the bowl, or before reference when removing the carburetor from either of
extended periods of storage. the 4-stroke youth models. Some steps may differ slightly
between models.
1. Turn the fuel valve “OFF” and drain the fuel from the
carb through the drain screw q.
2. Loosen or remove screw w retaining the choke cable
and disconnect the cable end from the choke arm.
3. Remove the carburetor mounting bolts e.
4. Loosen the intake boot clamp r between the
carburetor and air cleaner.

NOTE
Drain screw is located on the side of the float bowl.

1. Place a clean container beneath the bowl drain

spigot or bowl drain hose.
2. Turn the fuel valve to “OFF”.

5. Rotate the carb to allow access to remove the Slide

Cap t.

3. Loosen drain screw and allow fuel in the float bowl

and fuel line to drain completely.
4. Inspect the drained fuel for water or sediment.
5. Tighten drain screw.
6. Turn fuel valve to “ON”.

6. Remove the fuel line and vent lines. Remove

7. Inspect carburetor for fuel leaks carburetor from ATV.

8. Start machine and re-check for leaks.

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 FUEL SYSTEM

CARBURETOR DISASSEMBLY - 50CC 4. Remove the pilot jet d, main jet f, and emulsion
(MIKUNI) tube g from the carb body.
Use the following procedure to disassemble the Mikuni
carburetor used on the 50cc models.
1. Remove the four float bowl screws and float bowl y.

5. Note the position of both the pilot mixture screw h 4

and idle speed adjustment screw j and remove both
from the carb body.
2. Remove the float pin u, float i, and inlet needle o.

6. Remove the washer k and O-ring l from the pilot

mixture screw threaded hole in the carburetor body.
3. Remove the screw a retaining the inlet seat and
remove the retaining bracket and seat s from the
carburetor.

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FUEL SYSTEM

CARBURETOR DISASSEMBLY - 90CC 4. Remove the main jet y, emulsion tube u, and
(KEIHIN/SUNWORLD) needle jet i from the carburetor body.
Use the following procedure to disassemble the Keihin/
Sunworld carburetor used on 90cc models.
1. Remove the two float bowl screws and float bowl q.

5. Note the position of both the pilot mixture screw o

and idle speed adjustment screw a and remove both
from the carb body.

2. Remove the float pin w, float e, and inlet needle r.

3. Remove the pilot jet t.

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 FUEL SYSTEM

CARBURETOR CLEANING

WARNING
Protect eyes from contact with cleaner. Take
appropriate safety measures during these procedures.
Safety glasses and chemical resistant gloves are
required. Should you get cleaner in your eyes or if you
swallow cleaner, seek medical attention immediately.
Carburetor cleaners can be extremely caustic.
Extended periods of soaking can loosen the adhesive
sealer on the passage drill-way plugs. Do not soak
rubber or plastic components or O-rings in caustic
cleaning solutions. Irreparable damage may occur. Do
not use agitator-type carburetor cleaning equipment.
Rubber parts must be cleaned with mild detergent and
hot water only. 4
1. Thoroughly clean the carburetor body, jets, and all
passages with carburetor cleaner or electrical contact
cleaner.
2. If the carburetor is extremely dirty or contaminated
with fuel residue and varnish, soak for short periods
only in carburetor cleaner, and rinse in hot water.
3. Replace the jets if they have a buildup of fuel residue
or bacterial growth that cannot be removed. Even a
small amount of residue will reduce the flow
characteristics of the jet.
4. Verify all passages and jets are unobstructed by
spraying electrical contact cleaner through the
passages.

IMPORTANT
Do not use wire or welding tip cleaners as the orifice
size may be altered.

5. Use low pressure air to dry carburetor body and all

components.

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FUEL SYSTEM

CARBURETOR INSPECTION 3. Inspect the idle speed adjust screw tip for flat spots
1. Remove the carburetor slide assembly. Disassemble and the pilot mixture screw tip for damage. If any
the components and inspect for wear. Inspect slide damage is present on either screw, it must be
needle and look for discoloration, shiny spots, or an replaced.
area that looks different than the rest of the needle.
The middle to upper portion of the needle contacts
the needle jet and is the most likely wear point. If
slide needle shows signs of wear replace both the
needle and needle jet to prevent a rich condition.

2. Inspect the inlet needle tapered surface for any sign

of wear or damage. Be sure the spring loaded pin is
free moving and returns freely when pushed. The
inlet needle and seat should be pressure tested after
assembly.

4. Inspect the float bowl vent tube for cracks near the
bottom of the tube.
NOTE
A continuous fuel leak from the carburetor drain hose
can be a result of a cracked bowl vent tube.

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 FUEL SYSTEM

FLOAT HEIGHT ADJUSTMENT CARBURETOR ASSEMBLY

1. Place the carburetor on a flat level surface as shown 1. Replace parts in proper order. Refer to the parts
to remove weight from float arm. In the upward exploded view or “Disassembly” steps for further
position, the float will depress the needle plunger. detail
Slowly lower the float so the tab is just making
contact with the needle plunger. 2. Install the pilot air mixture screw, spring, washer, and
O-ring as an assembly (Mikuni Only). Lubricate the
O-Ring with oil or light grease before installation.
Turn the screw in until it lightly contacts the seat.
Back out the specified number of turns.

NOTE
The final pilot (idle) mixture must be adjusted with the
engine running. Refer to Chapter 2 for procedure.

Air Screw Base Setting(Set at Factory)Factory 4

Specification:50cc Mikuni: 2.5 Turns Out90cc Keihin/
Sunworld: 1.25 ± .5 Turns Out

2. With the carburetor at rest and level, slightly tilt the

carburetor back. The float should fall into the correct
position, with the float tab resting lightly on the inlet
needle valve pin without compressing the spring q.
The bottom of the float should be level with the float
bowl gasket surface with the float tab w.

IMPORTANT
When measuring float height, verify the float tab is not
pressing down on the needle spring-loaded plunger.

NOTE
If the float is past parallel with the mating surface, the
carburetor has likely been tilted back too far and the
float tongue is compressing the needle valve pin.

3. If adjustment is required, carefully bend the float tab

up or down until the float is parallel with the float bowl
gasket surface..

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FUEL SYSTEM

NEEDLE AND SEAT LEAK TEST

1. Install the float bowl.
2. Invert the carburetor and install a MityVac® (PN
2870975) to the fuel inlet fitting.
3. Apply 5 PSI pressure to inlet fitting. The needle and
seat should hold pressure indefinitely. If not, inspect
needle and seat and seat O-ring or gasket.

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4.16 © Copyright Polaris Industries Inc.
 FUEL SYSTEM

FUEL TANK EXPLODED VIEW

FUEL TANK REMOVAL FUEL VALVE LOCATION
See Body Removal, page for body removal Outlaw 50 / Outlaw 90
procedures to gain access the fuel tank.
1. Completely drain fuel from fuel tank. Be sure the fuel
valve is set to “RES” to get the majority of the fuel
drained from the tank.
2. Remove the vent line near the filler neck.
3. Remove the two bolts that attach the fuel tank to the
frame.

4. Carefully lift up on the fuel tank.

5. Place a shop rag or towel underneath the tank and
remove both fuel lines from the tank.

6. To reinstall the tank, reverse the removal procedure.

Be sure to torque the tank mounting bolts.

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FUEL SYSTEM

Sportsman 90 FUEL VALVE SERVICE

OUTLAW 50 / OUTLAW 90
To service the fuel valve:
1. Turn the fuel valve to “OFF” and remove the fuel line
at the carburetor fuel inlet. Turn the fuel valve to
“RES” and completely drain all the fuel from the fuel
tank into a suitable container.
2. Turn the fuel valve “OFF”.
3. Remove line clamps and fuel lines from the fuel
valve.
4. Remove the fasteners retaining the fuel valve and
remove the valve.
5. The fuel valve has a sediment bowl to catch moisture
and debris. Remove the sediment bowl and inspect
the valve for damage or debris. Replace the fuel
valve if damaged.

6. Reverse procedures to reinstall fuel valve.

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 FUEL SYSTEM

FUEL VALVE LAYOUT

Outlaw 50 / Outlaw 90

Sportsman 90

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FUEL SYSTEM

AIR FILTER
AIR CLEANER EXPLODED VIEW
90cc Model Shown

ITEM QUANTITY DESCRIPTION

q 1 Clamp

w 1 Boot

e 1 Hose, Drain

r 1 Clip, Drain Hose

t 4 Clip, Air Cleaner Cover

y 1 Box, Air Cleaner

u 1 Screen Filter

i 1 Foam Filter

o 1 Cover, Air Cleaner

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 FUEL SYSTEM

TROUBLESHOOTING
FUEL STARVATION / LEAN MIXTURE POOR IDLE
Symptoms: Hard start or no start, bog, backfire, popping Idle Too High
through intake / exhaust, hesitation, detonation, low
power, spark plug erosion, engine runs hot, surging, high • Idle adjusted improperly / idle mixture screw
idle, idle speed erratic. damaged
• Throttle cable sticking, improperly adjusted, routed
• No fuel in tank incorrectly
• Restricted tank vent, or routed improperly • Choke cable sticking, improperly adjusted, routed
• Fuel lines or fuel valve restricted incorrectly
• Fuel filter plugged • Plugged or restricted pilot jet
• Carburetor vent line(s) restricted
• Plugged or restricted inlet needle and seat screen or
inlet passage Idle Too Low
• Clogged jets or passages
• Choke cable bending or incorrectly adjusted
4
• Float stuck, holding inlet needle closed or inlet
needle stuck • Idle speed set incorrectly
• Float level too low • Idle mixture screw misadjusted or damaged
• Intake air leak (throttle shaft, intake ducts, airbox or • Belt dragging
air cleaner cover) • Ignition timing incorrect
• Jet needle position incorrect • Worn jet needle / needle jet
• Incorrect pilot screw adjustment • Plugged or restricted pilot jet

Erratic Idle
RICH MIXTURE
• Choke cable bending or incorrectly adjusted
Symptoms: Fouls spark plugs, black, sooty exhaust
• Throttle cable incorrectly adjusted
smoke, rough idle, poor fuel economy, engine runs
• Air leaks, dirty carburetor passages (pilot circuit)
rough/ misses, poor performance, bog, engine loads up,
• Pilot mixture screw damaged or adjusted incorrectly
backfire.
• Tight valves
• Ignition timing incorrect
• Air intake restricted (inspect intake duct) • Belt dragging
• Air filter dirty / plugged • Dirty air cleaner
• Choke plate sticking, incorrectly adjusted choke • Engine worn
• Choke cable binding or improperly routed • Spark plug fouled
• Incorrect pilot air / fuel screw adjustment • Idle speed set incorrectly
• Faulty inlet needle and seat • Worn jet needle / needle jet
• Faulty inlet needle seat O-Ring • Plugged or restricted pilot jet
• Float level too high
• Poor fuel quality (old fuel)
• Loose jets
• Worn jet needle / needle jet or other carburetor parts
• Dirty carburetor (air bleed passages or jets)
• Weak or damaged choke plate return spring
• Fouled spark plug

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FUEL SYSTEM

NOTES

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 BODY / STEERING / SUSPENSION

CHAPTER 5
BODY / STEERING / SUSPENSION
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
BODY REMOVAL - OUTLAW 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
OUTLAW 50 - BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
FOOTWELL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
FRONT BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
OUTLAW 50 - BODY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
BODY REMOVAL - OUTLAW 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
REAR CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
SIDE PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
FOOTWELL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 5
FRONT CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
FRONT BUMPER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
OUTLAW 90 - BODY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
BODY REMOVAL - SPORTSMAN 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
REAR CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
SIDE PANEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
FOOTWELL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
FRONT CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
BUMPER AND RACK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
SPORTSMAN 90 - BODY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
INDICATOR LIGHT / IGNITION SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
50CC SHOCKS AND SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
90CC SHOCKS AND SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
FRONT SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
REAR SHOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
FRONT CONTROL ARM - 50CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
CONTROL ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
CONTROL ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
FRONT A-ARM - 90CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
A-ARM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
A-ARM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
SWING ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
STEERING - 50CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
STEERING - 90CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
STEERING ASSEMBLY EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
STEERING POST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
TIE ROD REMOVAL / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29

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BODY / STEERING / SUSPENSION

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
OUTLAW 50 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
OUTLAW 90 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
SPORTSMAN 90 EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.30
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.31

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 BODY / STEERING / SUSPENSION

GENERAL INFORMATION
SPECIAL TOOLS TORQUE SPECIFICATIONS
2870872 SUSPENSION FASTENERS

Shock Spanner Wrench Fastener Torque

A–Arm Attaching Bolt 25 ft-lbs (34 Nm)
Front: 25 ft-lbs (34 Nm)
Shock Mounting Bolts
Rear: 36 ft-lbs (49 Nm)

50cc: 30 ft-lbs (41 Nm)

Swing Arm Mounting Bolt
90cc:65 ft-lbs (88 Nm)

STEERING FASTENERS
Fastener Torque
Handlebar Adjuster Block 84 in-lbs (10 Nm)

Inner Tie Rod Bolts 25 ft-lbs (34 Nm) 5

Outer Tie Rod Bolts 25 ft-lbs (34 Nm)
Bosch Automotive Service Solutions: 1-800-328-6657
or http://polaris.service-solutions.com/ Tie Rod Jam Nuts 13 ft-lbs (18 Nm)
Steering Post Mount Nuts 16 ft-lbs (22 Nm)
Steering Post Nut 40 ft-lbs (54 Nm)

FINAL DRIVE FASTENERS

Fastener Torque
Front Wheel Spindle Nut 44 ft-lbs (59 Nm)

Rear Wheel Hub Nut 58 ft-lbs (79 Nm)

Front / Rear Wheel Bolts 22 ft. lbs. (30 Nm)

Front: 87 in-lbs (9.8 Nm)
Sprocket Bolts
Rear: 16 ft-lbs (22 Nm)

Chain Tensioner Bolt 84 in-lbs (10 Nm)

Bearing Carrier Mounting 40 ft-lbs (54 Nm)
Bolts
Chain Guard Bolts 16 ft-lbs (22 Nm)

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BODY / STEERING / SUSPENSION

BODY REMOVAL - OUTLAW 50

OUTLAW 50 - BODY REMOVAL 4. Remove or loosen the front body attachment bolts
under the running lights.
1. Lift up on the seat latch and remove the seat.

5. Remove the screws attaching the front cover to the

2. Remove the four bolts retaining the body. body. There are two screws located in front and two
screws located behind the front cover.

3. Remove the four fasteners attaching the body to the

footwells on each side. 6. Remove the running light adjustment screw from
each side.

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 BODY / STEERING / SUSPENSION

7. Unhook the running light harnesses and completely 3. Remove the 6 screws and lift the removable footwell
remove the front cover with the running lights off.
attached.

4. Remove the 4 screws attaching the main footwells to

8. Remove the fuel tank cap and carefully remove the the frame on each side and remove the footwells.
body from the frame. 5
FOOTWELL REMOVAL
1. Remove the 4 fasteners attaching the body to the
footwells on each side.

FRONT BUMPER REMOVAL /

INSTALLATION
1. Remove the four mounting bolts retaining the front
bumper and remove the bumper from the ATV.
2. Remove the 6 rubber plugs from the removable
footwell to access the 6 screws.

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BODY / STEERING / SUSPENSION

2. Reverse the previous procedure to reinstall the

bumper.
3. Torque mounting bolts to specification.

TORQUE
Front Bumper Mount Bolts:
87 in-lbs (9.8 Nm)

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 BODY / STEERING / SUSPENSION

OUTLAW 50 - BODY EXPLODED VIEW

ITEM DESCRIPTION TORQUE

q Body Fasteners 43 in-lbs (5 Nm)

w Footwell / Riser Fasteners 87 in-lbs (10 Nm)

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BODY / STEERING / SUSPENSION

BODY REMOVAL - OUTLAW 90

REAR CAB REMOVAL 3. Remove the two fasteners attaching the rear cab
1. Lift up on the seat latch and remove the seat. supports to the frame. There is one on each side
under the rear cab.

2. Remove the four bolts retaining the rear cab and the
4. Remove the three fasteners on each side attaching
two screw inserts retaining the rear portion of the
the footwells to the rear cab.
side panels to the rear cab.
5. Remove the rear cab from ATV.

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 BODY / STEERING / SUSPENSION

SIDE PANEL REMOVAL

1. Remove the seat.
2. Remove the two insert fasteners near the front
portion of the side panel and the screw insert near
the rear portion of the side panel.

5
3. Repeat step 2 to remove the other side panel.

FOOTWELL REMOVAL
1. Remove the six fasteners attaching the front and
rear cab to the footwells on each side.

2. Remove the four bolts attaching the footwell to the

frame support.
3. Repeat steps 1 and 2 to remove the other side if
required.

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BODY / STEERING / SUSPENSION

FRONT CAB REMOVAL 4. Disengage the locking tabs attaching the front cab to
1. Remove the front cab cover by carefully lifting up on the fuel tank cover and remove the front cab from the
the cover to disengage the plastic tabs. ATV.
5. Remove the fuel tank cap to allow the tank cover to
be removed if required.

2. Remove the two screw inserts attaching the front cab

to the fuel tank cover.

FRONT BUMPER REMOVAL /

INSTALLATION
1. Remove the four mounting bolts retaining the front
bumper and remove the bumper from the ATV.

3. Remove the two bolts under the front portion of the

front cab. There is one on each side under the front
cab.

2. Reverse the previous procedure to reinstall the

bumper.
3. Torque mounting bolts to specification.

TORQUE
Front Bumper Mount Bolts:87 in-lbs (9.8 Nm)

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 BODY / STEERING / SUSPENSION

OUTLAW 90 - BODY EXPLODED VIEW

ITEM DESCRIPTION TORQUE

q Body Fasteners 43 in-lbs (5 Nm)

w Footwell / Riser Fasteners 87 in-lbs (10 Nm)

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BODY / STEERING / SUSPENSION

BODY REMOVAL - SPORTSMAN 90

REAR CAB REMOVAL 3. Remove the four bolts retaining the rear cab. Also
1. Lift up on the seat latch and remove the seat. The remove the two screw inserts attaching the rear
seat latch is located under the LH rear fender area portion of the side panels to the rear cab.

2. Remove the two bolts in the rear rack attaching the 4. Remove the four fasteners and one screw insert on
rear cab and rack to the rear cab supports. each side attaching the footwells to the rear cab.
5. Disconnect the tail light and remove rear cab from
the ATV.

SIDE PANEL REMOVAL

1. Remove the seat
2. Remove the two screw inserts from the side panel.

3. Repeat step 2 to remove the other side panel.

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 BODY / STEERING / SUSPENSION

FOOTWELL REMOVAL 3. Remove all eight fasteners retaining the front rack
1. Remove the eight fasteners and one screw insert and remove the rack from the ATV.
attaching the front and rear cab to the footwells on
each side.

4. Remove the two lower bolts retaining the front rack

support and remove the support. 5
2. Remove the four bolts attaching the footwell to the
frame support.
3. Repeat steps 1 and 2 to remove the other side if
required.

FRONT CAB REMOVAL

1. Remove the three bolts and two screws retaining the
front bumper to the ATV. The two screws are on the
backside of the front bumper and attach the bumper
to the front cab.

5. Remove the two screw inserts attaching the front cab

to the front cab cover under the handle bar pod.

2. Disconnect the daytime running lights and remove

the front bumper.

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BODY / STEERING / SUSPENSION

6. Disengage the locking tabs attaching the front cab

cover to the front cab and remove the cover.

7. Remove the fuel cap and carefully lift up and pull the
front cab towards the rear of the ATV to completely
remove it.

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 BODY / STEERING / SUSPENSION

BUMPER AND RACK REMOVAL

ITEM TORQUE

q 87 in-lbs (10 Nm)

w 16 ft-lbs (22 Nm)

SPORTSMAN 90 - BODY EXPLODED VIEW

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ITEM DESCRIPTION
q 43 in-lbs (5 Nm)

w 87 in-lbs (10 Nm)

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INDICATOR LIGHT / IGNITION SWITCH 3. To remove the indicator lights and/or ignition switch,
REPLACEMENT remove the retaining nut (s) and remove the
component.
1. Remove the three screws retaining the upper portion
of the pod.

NOTE
5
2. Disconnect the ignition switch harness and/or
indicator light harnesses. The indicator lights are a complete assembly. Bulb
replacement is not possible.

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SUSPENSION
50CC SHOCKS AND SPRINGS FRONT SHOCK REMOVAL
1. Elevate front end of the ATV off the ground to remove
shock spring tension.

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the upper shock mounting bolt from the

frame and the lower shock mounting bolt from the
front suspension arm / A-arm.

90CC SHOCKS AND SPRINGS

3. Replace the shock or spring as required.

4. Install shock
5. Torque shock mounting bolts to specification.

TORQUE
Front Shock Mount Bolt:
ITEM DESCRIPTION TORQUE 25 ft-lbs (34 Nm)

q Front Shock Bolts 25 ft-lbs (34 Nm)

w Rear Shock Bolts 36 ft-lbs (49 Nm)

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REAR SHOCK REMOVAL

1. Elevate rear end of the ATV off the ground to remove
shock spring tension.

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the upper shock mounting bolt from the

frame and the lower shock mounting bolt from the
swing arm.

3. Replace the shock, spring or adjuster cam as

required.
4. Install the shock.
5. Torque shock mounting bolts to specification.

TORQUE
Rear Shock Mount Bolt:
36 ft-lbs (49 Nm)

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FRONT CONTROL ARM - 50CC

CONTROL ARM EXPLODED VIEW

ITEM DESCRIPTION TORQUE

q Right Control Arm -

w Grease Fittings -

e Left Control Arm -

r Upper Spindle Bushing -

t Lower Spindle Bushing -

y Left Spindle -

u Bushings (4 total) -

i Right Spindle -

o Control Arm Bolts 25 ft-lbs (34 Nm)

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CONTROL ARM REPLACEMENT 6. Remove the lower shock mounting fastener and
1. Elevate front end of ATV off the ground far enough to inner control arm fastener.
remove the wheel.

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the dust cap and cotter pin.

3. Remove wheel nut and remove wheel and hub as an
assembly.

7. Remove control arm from the ATV.

8. To reinstall, reverse steps 1 - 7. Torque all fasteners 5
to specification.

TORQUE
Inner Control Arm Bolt:
25 ft-lbs (34 Nm)
Front Shock Mount Bolt:
25 ft-lbs (34 Nm)
4. Remove the cotter pin from the upper spindle castle Wheel Nut: 44 ft-lbs (59 Nm)
nut and remove the nut.

5. Slide the spindle assembly out from the end of the

control arm.

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FRONT A-ARM - 90CC

A-ARM EXPLODED VIEW

ITEM DESCRIPTION TORQUE

q Right A-arm -

w Grease Fittings -

e Castle Nut 25 ft-lbs (34 Nm)

r Left A-arm -

t Upper Spindle Bushing -

y Lower Spindle Bushing -

u Left Spindle -

i Bushings (8 total) -

o Right Spindle -

a A-arm Bolts 25 ft-lbs (34 Nm)

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A-ARM REPLACEMENT 6. Remove the lower shock mounting fastener and the
1. Elevate front end of ATV off the ground far enough to inner A-arm fasteners.
remove the wheel.

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the dust cap and cotter pin.

3. Remove wheel nut and remove wheel and hub as an
assembly.

7. Remove A-arm from the ATV.

8. To reinstall, reverse steps 1 - 7. Torque all fasteners 5
to specification.

TORQUE
Inner Control Arm Bolt: 25 ft-lbs (34 Nm)
Front Shock Mount Bolt: 25 ft-lbs (34 Nm)
Wheel Nut: 44 ft-lbs (59 Nm)

4. Remove the cotter pin from the upper spindle castle

nut and remove the nut.

5. Slide the spindle assembly out from the end of the

control arm.

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SWING ARM REMOVAL 5. Remove the rear brake cable adjuster nut and pull
cable out from swing arm bracket.
1. Elevate rear end of ATV off the ground far enough to
remove the rear wheel(s).

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the dust cap and cotter pin from the LH rear
wheel
3. Remove LH rear wheel nut and remove wheel and
hub as an assembly.

6. Remove the two nuts and bolts retaining the axle

housing to the rear swing arm.

4. Remove the brake drum housing retaining nuts (50cc

models only).

7. Remove the rear brake drum housing and remove

the rear brake shoes.

CAUTION
Springs are under tension. Wear safety glasses and
use caution when removing springs.Severe injury can
result.

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8. Remove the two bolts retaining the inner brake 11. Slide axle out of the axle housing and rear sprocket
housing to the axle housing and slide inner housing and remove the housing and sprocket assemblies.
off the axle.

9. Remove the two bolts retaining the chain guard and 12. 50cc - Remove the two through-bolts, exhaust
remove the guard. mount bolt and lower shock mounting bolt from the 5
swing arm and remove the swing arm from the ATV.

10. Rotate the axle housing far enough forward to

remove the chain from the sprocket. 90cc- Remove the one through-bolt as shown in the
image below.

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13. To reinstall, reverse steps 1 - 12.

NOTE
When installing the axle nuts on 50cc models, torque
the first nut. Then tighten the second jam nut against
the first nut and torque to the same value.

TORQUE
Axle Nut (50cc):
43 ft. lbs. (58 Nm)

14. Torque all other fasteners to specification. See

Torque Specifications, page 5.3

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STEERING - 50CC
STEERING ASSEMBLY EXPLODED VIEW 2. Remove the upper steering post mounting bolts.

3. Remove the inner tie-rod nuts and the steering post

nut.
5

ITEM TORQUE

q 16 ft-lbs (22 Nm)

w 25 ft-lbs (34 Nm)

e 40 ft-lbs (54 Nm)

STEERING POST REMOVAL

1. Remove handlebar fasteners and retainer block.
4. Carefully remove the steering post from the ATV.
5. To reinstall, reverse steps 1 - 4. Torque all fasteners
to specification. See Steering Assembly Exploded
View, page 5.27

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STEERING - 90CC
STEERING ASSEMBLY EXPLODED VIEW 2. Remove the upper steering post mounting bolts.

3. Remove the inner tie-rod nuts.

ITEM TORQUE

q 16 ft-lbs (22 Nm)

w 25 ft-lbs (34 Nm)

e 40 ft-lbs (54 Nm)

STEERING POST REMOVAL

1. Remove handlebar fasteners and retainer block.

4. Remove the steering post nut.

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5. Remove the two nuts retaining the bearing plate. TIE ROD REMOVAL / ADJUSTMENT
Steering tie rods can be replaced by removing the rod-
end castle nut at the steering post and spindle.
Tighten inner and outer tie rod bolts and jam nuts to
specification

6. Carefully remove the steering post from the ATV.

7. To reinstall, reverse steps 1 - 6. Torque all fasteners
to specification. See Steering Assembly Exploded
View, page 5.28
5

NOTE
See Toe Adjustment, page for Toe Alignment
procedure.

TORQUE
Inner / Outer Tie Rod Nut: 25 ft-lbs (34 Nm)
Tie Rod Jam Nut: 13 ft-lbs (18 Nm)

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HANDLEBAR
OUTLAW 50 EXPLODED VIEW SPORTSMAN 90 EXPLODED VIEW
1. Install the lower clamps. (circle)

ITEM TORQUE
2. Proceed to Brake Lever Travel, page 2.34.
q 42 in-lbs (5 Nm)
OUTLAW 90 EXPLODED VIEW
w 84 in-lbs (10 Nm)

e 25 ft-lbs (34 Nm)

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DECAL REPLACEMENT

WARNING
The following procedure involves the use of an open
flame. Perform this procedure in a well-ventilated area,
away from gasoline or other flammable materials. Be
sure the area to be flame treated is clean and free of
gasoline or flammable residue.
Do not flame treat components that are installed on the
vehicle. Remove the component from the vehicle
before flame treating.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame
treated” prior to installing a decal to ensure good
adhesion. A bonus of the flame treating procedure is it
can be used to reduce or eliminate the whitish stress
marks that are sometimes left after a fender or cab is
bent, flexed, or damaged.

To flame treat the decal area: 5

1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.

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NOTES

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CHAPTER 6
BRAKES
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
FRONT BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
EXPLODED VIEW (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
WHEEL BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
BRAKE DRUM BACKING PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
BRAKE SHOE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
FRONT BRAKE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7
REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
EXPLODED VIEW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8
REAR BRAKE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
BRAKE LEVER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12

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BRAKES

SPECIFICATIONS
GENERAL SPECIFICATIONS
FRONT BRAKE DRUM
Item Standard Service Limit
Brake Shoe Thickness 0.10” (2.54 mm) 0.05” (1.27 mm)

Brake Drum Inner Diameter 3.35" / (85.09 mm) 3.38" / (88.85 mm)

REAR BRAKE DRUM

Item Standard Service Limit
Brake Shoe Thickness 0.15” (3.81 mm) 0.08" / (2 mm)

Brake Drum Inner Diameter 5.05" / (128.27 mm) 5.08" / (129.0 mm)

TORQUE SPECIFICATIONS
ITEM TORQUE
Brake Arm Retaining Bolts 43 in-lbs (4.9 Nm)
Axle Housing Flange Nuts or 40 ft-lbs (54 Nm)
Brake Plate Bolts
Chain Guard Bolts 16 ft-lbs (22 Nm)
Rear Brake Drum Axle Nuts (50cc) -

NOTE
Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are used when
torquing certain bolts and fasteners.

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 BRAKES

FRONT BRAKES
EXPLODED VIEW (FRONT)

ITEM DESCRIPTION TORQUE

q Brake Cables -

w Return Spring -

e Brake Shoe -

r Brake Cam -

t RH Brake Arm -

y RH Plate -

u LH Brake Arm -

i LH Plate -

o Bolts 43 in-lbs (5 Nm)

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BRAKES

WHEEL BEARING INSPECTION 5. Inspect the outer seal w and outer bearing e for
wear or damage.
1. Elevate front end of ATV off the ground far enough to
remove the wheel.

CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Serious injury may occur if vehicle tips or falls.

2. Remove the dust cap and cotter pin.

3. Remove wheel nut and remove wheel and hub as an
assembly.

6. Flip the wheel hub and inspect the inner seal r and
inner bearing t for wear or damage.

4. Remove the outer bearing spacer q from the wheel

hub.

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 BRAKES

BRAKE DRUM BACKING PLATE REMOVAL

1. If service is required to backing plate components, 3. Inspect spindle shaft surface for pitting or other
remove the cotter pin q retaining the backing plate to damage. Replace spindle assembly if necessary.
the spindle.

2. Remove the backing plate assembly from the spindle

shaft assembly.
6

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BRAKES

BRAKE SHOE REMOVAL 3. Inspect the brake shoe pad material. Replace if worn
beyond specification.
1. Reinstall brake backing plate and components if
previously removed.
Using a suitable tool, lift up on the spring near the
retainer stud as shown and remove the spring.

MEASUREMENT
Front Brake Shoe Pad Thickness:
Service Limit: 0.05” (1.27 mm)

CAUTION 4. Inspect the shoe retainer stud w and brake cam e

Spring is under tension. Wear safety glasses and use for wear or damage.
caution when removing spring.
Severe injury can result.

2. Slide brake shoes q off retainer stud and remove

from backing plate.

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 BRAKES

FRONT BRAKE ASSEMBLY

1. Use the illustration below as reference when
reassembling the front brake components.

6
ITEM DESCRIPTION
q Brake Cable

w Return Spring

e Brake Shoe

r Retainer Spring

t Right Brake Arm

y Right Brake Plate

2. Inspect oil seals and bearings for wear or damage

upon assembly. Replace bearings and seals if
necessary.
3. Install the wheel hub and tighten the front spindle nut
to specification.

TORQUE
Front wheel Spindle Nut:
44 ft-lbs (59 Nm)

NOTE
Perform the Brake Lever Travel, page 2.34 procedure
when finished.

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BRAKES

REAR BRAKE
EXPLODED VIEW (REAR)

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 BRAKES

ITEM DESCRIPTION TORQUE

q Brake Cable —

w Nut —

e Adjustment Nut —

r Spacer —

t Cable Spring —

y Drive Chain Guard Bolts 87 in-lbs (10 Nm)

u Plate —

i Spring —

o Brake Arm —

a Brake Arm Bolt 43 in-lbs (5 Nm)

s Brake Cam —

d Brake Shoe —

f Protective Rubber —

g Brake Drum —
6
h Axle Housing Bolt 40 ft-lbs (54 Nm)

j Oil Seal —

k Bearing —

l Spacer Tube —

1( Axle Housing —

2) Flange Nut 40 ft-lbs (54 Nm)

2! Axle Housing Bolt 40 ft-lbs (54 Nm)

2@ Nut —

2# Bolts —

2$ Fixed Shaft —

2% Bearing —

2^ Oil Seal —

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BRAKES

REAR BRAKE SERVICE 5. Carefully remove the retainer springs and brake
shoes
1. Follow the Swing Arm Removal, page procedure to
the point where the rear brake drum housing can be CAUTION
accessed.
Springs are under tension. Wear safety glasses and
NOTE use caution when removing springs.
Severe injury can result.
You do not need to fully disassemble the rear axle /
swing arm to service the rear brakes.

2. Once the rear brake drum housing has been

removed, clean and inspect the brake drum housing.
3. Inspect the brake shoe contact surface and the axle
housing seal surface for excessive wear, pitting, or
damage. Replace if necessary.
4. Inspect the protective rubber gasket q for nicks or
other damage. Replace if necessary.

6. Remove brake shoes.

7. Inspect the brake shoe pad material. Replace if worn
beyond specification.

MEASUREMENT
Rear Brake Shoe Pad Thickness:
Service Limit: 0.08” (2 mm)

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 BRAKES

8. Inspect the backing plate seal w and brake cam e 10. Reinstall rear brake components. Use illustration
for excessive wear or damage. Replace if necessary. below as a reference.

9. Inspect all oil seals and bearings for wear or damage

upon assembly. Replace bearings and seals if
necessary.

ITEM DESCRIPTION
q Rear Brake Cable

w Rear Brake Drum

e Rubber Gasket

r Brake Cam

t Brake Arm Spring

y Brake Arm

u Brake Shoes

i Seal

o Bearing

a Spacer Tube

TORQUE
Axle Nut:
43 ft-lbs (58 Nm)
Axle Jam Nut:
43 ft-lbs (58 Nm)

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BRAKES

11. Install the swing arm, see Swing Arm Removal,

page . Torque the rear wheel hub nut (s) to
specification.

TORQUE
Rear Wheel Hub Nut:
58 ft-lbs (79 Nm)

BRAKE LEVER ADJUSTMENTS

Perform Front Brake Adjustment, page 2.35 Rear Brake
Adjustment, page 2.36 procedures outlined in Chapter 2
after completing any brake service.

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 CVT

CHAPTER 7
CVT
CVT SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
CVT MAINTENANCE / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
CVT SYSTEM DRYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
CVT OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
CLUTCH COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DRIVE BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
DRIVE BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
CLUTCH COVER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE CLUTCH DISASSEMBLY AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
DRIVE CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
DRIVEN CLUTCH DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
DRIVEN CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14

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CVT

CVT SYSTEM

WARNING DRIVE CLUTCH OPERATION

Drive clutches primarily sense engine RPM. The major
All CVT maintenance or repairs should be performed by component which controls shifting function are the shift
a certified Polaris Master Service Dealer (MSD) centrifugal weights (rollers) inside the moveable sheave.
technician who has received the proper training and Whenever engine RPM is increased, centrifugal force is
understands the procedures outlined in this manual. created, causing the rollers to push against the cam plate
Because of the critical nature and precision balance and force the moveable sheave toward the drive belt.
incorporated into the CVT components, it is absolutely This motion pinches the drive belt between the spinning
essential that no disassembly or repair be made without sheaves and causes it to rotate, which in turn rotates the
factory authorized special tools and service procedures. driven clutch. If belt speed is sufficient, centrifugal friction
shoes on the driven clutch overcome their return spring
The Polaris Variable Transmission (CVT) consists of pressure and swing outward against the transmission
three major assemblies: 1) The Drive Clutch; 2) The drive hub, and the vehicle (if in gear) begins to move.
Driven Clutch; and 3) The Drive Belt. The internal
components of the drive clutch and driven clutch control At lower RPM, the drive belt rotates low in the drive
engagement (initial vehicle movement), clutch upshift clutch sheaves. As engine RPM increases, centrifugal
and backshift. During the development of a Polaris ATV, force causes the drive belt to be forced upward on drive
the CVT system is matched first to the engine power clutch sheaves, changing the ratio of the drive to driven
curve; then to average riding conditions and the vehicle’s clutch from low to high.
intended usage. Therefore, modifications or variations of
components at random are never recommended. Proper DRIVEN CLUTCH OPERATION
clutch setup and careful inspection of existing CVT driven clutches primarily sense torque, but also
components must be the primary objective when react to RPM, applying and retracting the friction shoes
troubleshooting and tuning. according to the forces applied to it from the drive belt,
CVT MAINTENANCE / INSPECTION while at the same time reacting to the torque at the
transmission input shaft. If the torque resistance at the
Under normal operation the CVT system will provide
transmission input shaft is greater than the load from the
years of trouble free operation. Periodic inspection and
drive belt, the drive belt is kept at the outer diameter of
maintenance is required to keep the system operating at
the driven clutch sheaves (low ratio).
peak performance. The following list of items should be
inspected and maintained to ensure maximum As engine RPM and horsepower increase, the load from
performance and service life of CVT components. See the drive belt increases, resulting in the belt rotating up
“CVT Overheating / Diagnosis”See “CVT Overheating / toward the outer diameter of the drive clutch sheaves
Diagnosis” on page 7.4., page 7.4 for more information. and downward into the sheaves of the driven clutch. This
action, which increases the driven clutch speed, is called
1. Drive clutch rollers and bushings. Driven clutch upshifting.
rollers, pins, and spring.
Should the throttle setting remain the same and the
2. Clutch sheave faces. Clean and inspect for wear. vehicle is subjected to a heavier load, the torque sensing
3. CVT system sealing. The CVT system on 90cc driven clutch will close, forcing the drive belt back up
models is air cooled by fins on the drive clutch. The toward the outer diameter of the driven clutch. This also
fins create a low pressure area around the drive forces the belt downward into the sheaves of the drive
clutch, drawing fresh air in through the intake duct. clutch. This action, which decreases the driven clutch
The opening for this intake duct is located at a high speed, is called backshifting.
point on the vehicle. All connecting air ducts, as well In situations where loads vary and throttle settings are
as the clutch cover, must be sealed to ensure clean constant, the drive and driven clutches are continually
air is being used for cooling the CVT system. This shifting to maintain optimum engine RPM. At full throttle
also reduces the chance of water and other a perfectly matched CVT system should hold engine
contaminants entering the CVT area. RPM at the peak of the power curve. This RPM should
be maintained during clutch upshift and backshift. In this
respect, the CVT system is similar to a power governor.
Rather than vary throttle position, as a conventional
governor does, the CVT system changes engine load
requirements by either upshifting or backshifting.

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 CVT

CVT SYSTEM DRYING

NOTE
If operating the ATV in water, check the CVT cover and
other ATV components for water ingestion. Refer to
Owner’s Manual for Safe Riding Tips.

1. To drain any water that may be trapped inside the

CVT area, remove the CVT drain plug q and O-ring
located on the bottom of the crankcase and let the
water drain out. The CVT drain plug is shown at right.

2. To further expel water from the CVT area cover and to

dry out the CVT system, shift the transmission to
neutral and rev the engine slightly to expel the
7
moisture. This will also air-dry the belt and clutches.
3. Allow engine RPM to settle to idle speed, shift
transmission to lowest available range and test for
belt slippage. Repeat as needed.

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CVT

CVT OVERHEATING / DIAGNOSIS

During routine maintenance or whenever CVT system
overheating is evident, it’s important to check the inlet
and outlet ducts for obstructions. Obstructions to air flow
through the ducts will significantly increase CVT system
operating temperatures.

CVT Air Duct System (90cc Models Only)

ITEM DESCRIPTION
q Clamps

w Air Inlet Duct

e Air Outlet Duct

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 CVT

CLUTCH COVER REMOVAL DRIVE BELT REMOVAL

1. Remove the left foot rest.
1. Remove O-ring and nut from driven clutch.

2. Loosen the duct clamps and slide ducts upward off

cover. 2. Pull outer sheave of driven toward you and push belt
as far as possible into driven sheaves to create belt
slack.

3. Remove all screws and cover with kick start lever

attached.
3. Slide driven clutch off shaft with belt. Remove belt
from driven clutch sheaves and then from drive
clutch.

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CVT

DRIVE BELT INSTALLATION

NOTE
Clutch Cover and Driven Clutch must be removed prior
to Drive Belt Installation. See Clutch Cover Removal,
page 7.5

1. Install belt around the driven clutch sheaves and then

the drive clutch.
2. Replace Driven Clutch. See Driven Clutch Assembly,
page

CLUTCH COVER INSTALLATION

1. Install Clutch Cover on Clutch.
NOTE
Make sure to properly align the clutch cover with the
driven clutch post with the inside of the cover.

2. Install all screws into Clutch Cover.

TORQUE
87 in-lbs (10 Nm)

3. Replace the duct clamps and slide ducts to cover.

4. Replace the left foot rest.

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 CVT

DRIVE CLUTCH SERVICE

DRIVE CLUTCH DISASSEMBLY AND INSPECTION
1. Remove outer drive clutch sheave and drive belt. 4. Inspect surface of sleeve q for wear, pitting, or
Note parts assembly order. damage.

2. Slide sheave and cam plate off crankshaft as an 5. Inspect cam plate for wear on surface w and splines
assembly. e. Replace cover guides r as a set.
NOTE
When removing primary sliding sheave and cam plate
assembly, hold cam plate and sliding sheave together. 7
This prevents the rollers from falling out of the
assembly.

3. Remove cam plate.

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CVT

6. Inspect sheave faces t for grooves or wear. Check 8. Inspect the roller tracks u and both sides of the cam
bushings y and seals in the moveable sheave. The plate tabs i for wear. Compare the drive and
sleeve should be a close, smooth fit in the bushings deceleration side of the tabs to determine if drive side
and seals should fit tightly on the sleeve. is worn. Replace drive clutch assembly if tabs or roller
tracks are worn.

7. Remove and inspect each roller. Replace as a set if

any have flat spots or if worn (they should be
cylindrical).

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 CVT

DRIVE CLUTCH ASSEMBLY 3. Install the cam plate.

1. Apply a very light film of grease to the seal lips and

drive clutch sleeve. Then install the sleeve.

4. Install the bushing, primary sliding sheave and cam

plate assembly.
2. Install all rollers with open end facing inward toward
divider q (the side with inner bushing visible.)

NOTE
When installing the primary sliding sheave and the cam
plate assembly, hold the assembly together to prevent
the rollers from dislodging.

5. Open the sheaves of the secondary clutch and push

the belt down between the sheaves.
6. Install the driven clutch on the transmission input
shaft, looping the belt onto the drive clutch sleeve as
shown.

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CVT

7. Pinch the belt in the middle and install the outer drive
clutch sheave as far as possible. Hold outer sheave
in place.

8. Install the claw washer, engaging the inner spline of

the washer on the crankshaft and the outer claws w
in the sheave.

9. Install the drive hub, making sure the inner splines e

are engaged on the crankshaft.
10. Install flat washer and nut and torque to specification.

TORQUE
Drive Clutch Lock Nut:
29 ft-lbs (39 Nm)

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 CVT

DRIVEN CLUTCH SERVICE

DRIVEN CLUTCH DISASSEMBLY AND INSPECTION
1. Remove driven clutch assembly by removing O-ring
and nut.
CAUTION
Spring is under tension. Wear safety glasses and use
caution when removing spring. Severe injury can result.

2. Remove outer drive hub (transmission shaft hub).

5. Remove the outer roller pin cover by turning and

pulling up on the cover. Replace the two sealing O-
rings.

3. Remove drive belt.

4. Secure the driven clutch assembly in a soft jaw vise
or clamp. Loosen the retaining nut about 1 turn. Hold
downward pressure on the friction shoe plate, and
then remove the nut. Release pressure on plate and
remove the friction shoe assembly and driven spring.

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CVT

6. Remove rollers and pins using a needle-nose pliers 8. Inspect the condition of the secondary clutch drive
and inspect all components. Replace if any damage hub. Measure the inside diameter of the hub using a
or excess wear is found. Replace the o-rings and caliper and compare to specification. If either of these
seals anytime the driven is apart. measurements exceeds the limit, replace the drive
hub.

7. To replace friction shoes, remove E-clips that retain

the backing plate. Use a suitable tool to remove and
install the return springs connecting the shoes, using
care not to stretch the springs more than is
necessary.

MEASUREMENT
q 0.39” (1.0mm)

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 CVT

9. Use a vernier caliper to check the length of the

compression spring. At full extension, the
measurement should be no less than 2.74” (69.7
mm). If out of specification, replace the spring.

MEASUREMENT
Driven Clutch Hub I.D.
Service Limit: 4.43” (112.5 mm)
Driven Clutch Friction Shoe Thickness
Service Limit: .039” (1.0 mm)
Driven Compression Spring Length
Service Limit: 2.74” (69.7 mm)

10. Inspect the surface of the drive belt for uneven wear
7
or grease deposits. Using a vernier caliper, measure
the width of the belt. The service limit of the belt is
.626” (15.9 mm). If the width of the belt is less than
the service limit, or if the belt is worn, glazed or hour-
glassed, replace.

MEASUREMENT
CVT Drive Belt Width
Service Limit: .626” (15.9 mm)

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CVT

DRIVEN CLUTCH ASSEMBLY TORQUE

1. Insert new seals into the outer sheave assembly. Fill Driven Assembly Nut:
the outer sheave cavity with fresh grease and slide 52 ft-lbs (70 Nm)
onto the inner sheave shaft. Align and insert the (2)
roller/pin assemblies. Install new o-rings and the
3. Install the drive belt on driven clutch and move belt as
outer roller pin cover. Place the washer onto the
far into the sheaves as possible.
threaded shaft and apply Loctite® 272™ to the
threads. 4. Loop the belt over the drive clutch and install driven
clutch on transmission shaft.
Outer Sheave Assembly
5. Install driven clutch hub, then the retaining nut and O-
ring. Torque retaining nut to specification.

ITEM DESCRIPTION
q Outer Cover
w O-rings
e Rollers and Pins
TORQUE
r Seals
Driven Clutch Nut:
24 ft-lbs (34 Nm)
2. Have an assistant available for final assembly. Install
the compression spring. Place the friction pad
assembly over the spring and compress the driven
assembly together with both hands. With the
assembly compressed and the threads exposed,
have an assistant thread a new assembly nut onto
the shaft. Secure the assembly in a clamping device
and torque the assembly nut to specification.

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 ELECTRICAL

CHAPTER 8
ELECTRICAL
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
ELECTRICAL SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
SWITCHES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
BRAKE LEVER SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
TETHER SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
THROTTLE RELEASE SWITCH (TRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
TRS SWITCH ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
KEY SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
LEFT HAND SWITCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
DAYTIME RUNNING LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
“DRL” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
“DRL” LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7
TAIL LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
TAIL LIGHT LAMP REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
INDICATOR LAMPS (90CC MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
INDICATOR LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
TRANSMISSION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
TRANSMISSION SWITCH - CIRCUIT BREAKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11 8
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
IGNITION SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.12
IGNITION SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
RPM IGNITION LIMITER FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
RPM LIMITER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
IGNITION COIL TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
CDI OUTPUT TEST USING PEAK READING ADAPTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
PULSER COIL OUTPUT / RESISTANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.15
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
CHARGING SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
MAIN FUSE / FUSIBLE LINK LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
VOLTAGE REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
STATOR / ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
BATTERY MAINTENANCE SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
NEW BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
BATTERY REMOVAL - 50CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
BATTERY REMOVAL - 90CC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20

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ELECTRICAL

BATTERY CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21

BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
BATTERY VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
BATTERY LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.21
BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.22
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.22
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
STARTER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
STARTER MOTOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.23
STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
STARTER BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25
ARMATURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25
STARTER REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
STARTER SYSTEM TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.28

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GENERAL INFORMATION
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
Fluke® 77 Digital
PV-43568
Multimeter
2870836 Peak Reading Adaptor

2870630 Timing Light

8712100 or 8712500 Tachometer

Bosch Automotive Service Solutions: 1-800-328-6657

or http://polaris.service-solutions.com/

ELECTRICAL SYSTEM SERVICE NOTES

Reference the following notes when diagnosing electrical
problems.
• The ignition system timing is non-adjustable. The
specifications in Chapter 1 are intended for reference
only.
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that has a
low resistance value (under 10 Ohms), remember to
subtract meter lead resistance from the reading.
Connect the leads together and record the resistance.
The resistance of the component is equal to tested
value minus the lead resistance.
• Become familiar with the operation of the meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to
the owner’s manual included with the meter for more 8
information.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke® 77 Digital
Multimeter (PV-43568). This meter is acceptable for
use when diagnosing electrical problems. Readings
obtained with other meters may differ.
• Pay attention to the prefix on the multimeter reading
(K, M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be
tested. Disconnect it from the wiring harness or power
supply.

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SWITCHES AND CONTROLS

BRAKE LEVER SWITCHES TETHER SWITCH TEST
Each brake lever utilizes an electrical brake switch that
1. Disconnect wires from switch.
sends voltage to activate the starter relay and brake light.
2. Connect an ohmmeter across the two switch wires
1. Locate the brake switches on each of the brake (DG and BK/YE). With the boot installed, reading
levers. should indicate continuity. Replace the switch if there
2. Disconnect wire harness from brake switch and is greater than .5 ohms resistance.
connect an ohmmeter across the two switch wires.
The reading should be infinite (•)
3. Apply brake the brake lever (s) and check for
continuity between switch contacts. Replace switch if
there is no continuity or if the resistance is greater
than .5 ohms when the brake is applied with slight
pressure.

3. Pull tether boot from switch and check for an infinite

(∞) reading. Replace switch if continuity exists.

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THROTTLE RELEASE SWITCH (TRS) TRS OPERATION

Always check the throttle for smooth operation before When the throttle is closed (idle) the throttle arm
riding. Periodically check the throttle free play. depresses a small micro switch that limits engine rpm.
If adjustment is required, turn the adjustment nut w until
the free play falls within the acceptable limit.

When the throttle lever is pushed forward the throttle arm

moves off the micro switch and allows the engine rpm to
increase with lever movement.
MEASUREMENT

q 1/16” — 1/8” (1.5 — 3.2mm)

If the throttle cable would become hung up or stuck while

the ATV is being operated, the spring loaded throttle arm
will return back and depress the micro switch, limiting
engine rpm.

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TRS SWITCH ADJUSTMENT KEY SWITCH

1. Slide the boot off the throttle cable adjuster and jam The key switch can be tested with an ohm meter.
nut.

When the key switch is turned to the “ON” position, there

should be continuity between the red (RD) and brown/
white (BN/WH) wires.
When the key is turned to the “OFF” position, there
2. Set parking brake. should no continuity between any of the wires.
3. Start engine and set idle to specified RPM. KEY SWITCH CONTINUITY CHART
NOTE Color
Be sure the engine is at operating temperature. See RD BN/WH
Switch
Idle Speed Adjustment, page .
Position ON X X
4. Loosen the adjustment nut on in–line cable adjuster. OFF

LEFT HAND SWITCH ASSEMBLY

The following illustration shows the internal operation of
the LH switch assembly. If any part of the switch is faulty,
the entire LH switch assembly must be replaced.

5. Turn cable adjuster out until engine RPM begins to

increase.
6. Turn cable adjuster back in until throttle lever has 1/
16” (.16 cm) of travel before engine RPM increases.
7. Tighten lock nut securely and slide boot completely
in place to ensure a water–tight seal.

NOTE
Verify TRS switch plunger is held inward at idle
position.

8. Turn handlebars from left to right through the entire

turning range. If idle speed increases, check for
proper cable routing. If cable is routed properly and
in good condition, repeat adjustment procedure.

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DAYTIME RUNNING LIGHTS

“DRL” TEST Outlaw 50 / Outlaw 90:
The daytime running lights are powered by an AC current 1. Locate the lamp socket q & w below the front cover.
from the Generator / Stator. Rotate the socket about 1/4 turn and remove it from
If running lights are not working, perform the the housing.
following:
1. Disconnect the harness from the faulty light
2. Using a Volt Ohm Meter, measure the AC voltage
between the yellow red (YE/RD) and black (BK)
wires. Voltage above 5 VAC should be present when
unit is running
If voltage is present:
1. Replace the faulty bulb.
If voltage is not present:
1. The black wire should have continuity to ground. If
no continuity is present, check for an open in the
wiring harness or a poor connection. 2. Without twisting, pull the lamp out of the socket.

2. If black wire has good continuity to ground, check the 3. Apply Dielectric Grease PN 2871329 to the new bulb
wiring harness from the stator to the running lights. contacts and install.
There should be continuity between the (YE/RD) 4. Reinstall the socket into the housing and rotate
wire at the light connector and the (YE/RD) wire at about 1/4 turn.
the Generator / Stator.
5. Start the engine to make sure the lights come on. If
3. If continuity is good. Perform stator resistance tests the lights do not operate, check the charging system
by using the resistance chart located in the wiring and related wiring for possible malfunction.
diagram.
Sportsman 90:
4. Replace Generator / Stator if resistance is not within
6. Remove the light housing from the bumper. Separate
specification.
the housing by removing the four screws from the
rear cover.
7. Rotate the lamp socket counterclockwise about 1/4
8
turn and remove it from the housing.

8. Without twisting, pull the lamp out of the socket.

9. Apply Dielectric Grease PN 2871329 to the new bulb
contacts and install.
“DRL” LAMP REPLACEMENT 10. Reinstall the socket into the housing and rotate
If the daytime running lights do not operate, lamp clockwise about 1/4 turn.
replacement may be required. Install only the 11. Start the engine to make sure the lights come on. If
recommended replacement lamps. the lights do not operate, check the charging system
and related wiring for possible malfunction.

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TAIL LIGHT
TAIL LIGHT LAMP REPLACEMENT
If the tail light lamp does not work, the lamp may need to
be replaced.

1. Remove the two screws q securing the lens cover w

and remove the lens cover.
2. Remove the lamp e and replace it with a new
(recommended) lamp. Apply Dielectric Grease (PN
2871329) to the lamp terminals.
3. Test the light for proper operation.
4. Reinstall the lens cover.

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INDICATOR LAMPS (90CC MODELS)

INDICATOR LAMP REPLACEMENT 8. Turn ignition key to the “ON” position and shift the
Outlaw 90 / Sportsman 90: transmission into “Neutral” or “Reverse” to verify light
operation.
1. Remove the handlebar cover or pod to access the
lamps.
2. Disconnect the indicator light wire connections from
the harness.

9. If the lights do not operate, check battery voltage at

the light harness and check related wiring for
possible malfunction.

3. Remove the nut from the backside of the indicator

lamp.

4. Remove the lamp.

5. Install new lamp(s) into the cover or pod and secure
with retaining nut.
6. Apply dielectric grease to the wire connections of the
new lamp.
7. Reconnect wire connections and assemble the
handlebar cover or pod.

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TRANSMISSION SWITCH
TRANSMISSION SWITCH - CIRCUIT BREAKOUT

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TESTING REMOVAL
1. With the switch installed, use an ohmmeter to test 1. Remove the CVT cover. The indicator switch will be
continuity between the switch leads and engine visible between the drive and driven clutch. Refer to
ground. Clutch Cover Removal, page 7.5 for removal and
installation.
2. First, shift the transmission into “neutral” and test for
continuity between the DG/WH wire and ground. 2. Remove the two screws and pull on switch to release
from crankcase.
3. Then shift the transmission into “reverse” and test for
continuity between the DB wire and ground. In both 3. Inspect the shift indicator contacts, shift drum, pin
tests you should have continuity to ground. and spring q. Verify the pin is not sticking in the
drum or is damaged. Replace any worn or damaged
components.

INSTALLATION
1. Install spring and pin into shift drum.
2. Install switch with new O-ring. Route wires through
crankcase. Install screws. 8
3. Torque screws to specification.

Indicator Switch Screw:

50 in-lbs (5 Nm)

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IGNITION SYSTEM
OVERVIEW IGNITION SYSTEM TROUBLESHOOTING
The Youth ATV ignition system consists of a simple No Spark, Weak or Intermittent Spark
magneto-driven system that includes a stator Pulser Coil,
• No 12 volt power on brown (BN) wire at CDI box or no
CDI Box, Ignition Coil and related wiring / connectors.
CDI box ground path from the black/white (BK/WH)
Timing is non-adjustable on this ignition system. wire
• Spark plug gap incorrect
• Fouled spark plug
• Faulty spark plug cap or poor connection to high
tension lead
• Related wiring loose, disconnected, shorted, or
corroded
• Engine Stop switch or ignition switch faulty
• TRS switch misadjusted or faulty
• Poor ignition coil ground
• Faulty stator (measure resistance of all ignition related
windings)
• Incorrect wiring (inspect color coding in connectors
etc)
• Faulty ignition coil winding (measure resistance of
primary and secondary)
• Sheared flywheel key
• Flywheel loose or damaged
• Excessive crankshaft runout on magneto. (RH) end
should not exceed .005”
• Faulty CDI module

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IGNITION SYSTEM TESTING

Whenever troubleshooting an electrical problem, first check all terminal connections to be sure they are clean and
tight. Use the following flow chart as a guide for troubleshooting. NOTE: The brown (BN) wire on youth models
carries 12V key-on power.
Condition: No spark or intermittent spark.

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RPM IGNITION LIMITER FUNCTIONS IGNITION COIL TEST

NOTE
The CDI box reads the RPM signal from the stator. The
CDI box acts as a limiter by retarding the ignition timing
if RPM reaches the specified limit. In reverse gear, the
CDI box retards ignition timing and limits RPM once it
receives a ground path from the transmission switch
dark blue (DB) wire indicating the ATV is in reverse.
The CDI box can also receive a ground path from the
TRS switch causing the CDI box to retard timing and
limit RPM if the throttle cable becomes slack or stuck.

TEST DESCRIPTION RESISTANCE

Ignition Coil Primary Winding 0.2 Ω ± 20%
Ignition Coil Secondary Winding
(With Cap Installed) 8 K Ω ± 20%
(Without Cap Installed) 3 K Ω ± 20%
Spark Plug Resistor Cap 5KΩ

CDI OUTPUT TEST USING PEAK READING

ADAPTOR
Re-connect all wires to the CDI box. Disconnect the
white/blue (WH/DB) CDI output wire from ignition coil
primary terminal. Install the Peak Reading Adaptor (PV-
39991) to your meter and connect one meter lead to
engine ground and the other to the (WH/DB) CDI Output
wire at the ignition coil. Set meter to read DC Volts.
Crank engine and verify CDI output to the ignition coil.
RPM LIMITER SPECIFICATIONS When finished, reconnect CDI output wire to ignition coil.

IGNITION OUTPUT CONNECT METER

MODEL MAX RPM READING
TIMING TEST LEADS TO:
50cc 7400 33.5° BTDC CDI WH/DB to Engine 180 DC Volts ±
90cc 8400 33.5° BTDC Output Ground 20%

NOTE
There are no timing advance marks stamped on the
flywheel to read with a timing light.

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PULSER COIL OUTPUT / RESISTANCE

TESTS
Disconnect the 4-wire connector at the CDI box. Install
the Peak Reading Adaptor (PV-39991) to your meter and
connect one meter lead to the dark blue / black wire (DB/
BK) and the other to engine ground. Set meter to read
DC Volts. Crank engine and verify pulser coil output.

CONNECT READING
VOLT-
METER (WITH PEAK READING
AGE
LEADS ADAPTER)
TEST
BETWEEN:
DB/BK to 5 DC Volts minimum @
Pulser
Engine cranking RPM
Coil
Ground

If readings are within specifications, test the resistance

value of the pulser coil. When finished, reconnect the 4-
wire connector to CDI box.
CONNECT METER
OHM TEST LEADS TO: Ω READING
Pulser Coil Blue to Black 150 Ω ± 20%

Pulser Coil Testing

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CHARGING SYSTEM
CHARGING SYSTEM TESTING
Whenever charging system problems are suspected, proceed with the following system checks:

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MAIN FUSE / FUSIBLE LINK LOCATION negative ‘-’ lead to position #2. There should be
The main electrical system on all youth models is measurable resistance. Reverse the leads and test.
protected by a 7 amp fuse and a fusible link. See There should be no continuity. Positions #3 and #4
illustrations for component locations. should be tested the same and achieve the same results.

Failure of either fuse mechanism indicates that a flow of

excess current has occurred and should be investigated
before replacement of fuse.

NOTE
Use only the recommended fuse capacity, as use of a
higher amperage fuse to correct blown-fuse situations
could lead to electrical component damage.

Fusible Link Kit: PN 2202147

VOLTAGE REGULATOR / RECTIFIER

The voltage regulator / rectifier is located under the LH
rear fender on the 90cc models and under the RH front
fender on the 50cc models.
The regulator diodes can be tested with an ohm meter.
Attach the positive ‘+’ lead to position #1 and the

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STATOR / ALTERNATOR TESTS TEST 2: Measure AC voltage output of each stator leg.
Two tests can be performed using a multimeter to Test at cranking rpm with a voltmeter set to read AC
determine the condition of the stator (alternator). volts.
1. Turn over the engine with the starter motor.
2. First measure from the red wire (RD) to engine
ground. Compare readings to specifications.
3. Next measure from the yellow wire (YE) to engine
ground. Compare readings to specifications.

CONNECT
AC OUTPUT AC
METER
TEST READING
LEADS TO:

Battery Charge RD to Ground 8 VAC

Coil YE to Ground 5 VAC

NOTE
To check the charging system output further, start the
engine and perform the same tests. Voltage should
TEST 1: Measure resistance value of each stator leg.
increase with increased RPM.
1. Measure the resistance value of the stator legs. Use
the following chart as a reference when testing.
Maximum Stator Output6.5 Amps @ W.O.T.
CONNECT METER
OHM TEST Ω READING
LEADS TO:
BK to Ground 0.1 Ω ± 20%
Battery
Charge Coil BK to RD 0.9 Ω ± 20%
BK to YE 0.5 Ω ± 20%

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BATTERY
BATTERY MAINTENANCE SERVICE NOTES NEW BATTERY ACTIVATION
To ensure maximum service life and performance from a
WARNING new battery, perform the following steps.
CALIFORNIA PROPOSITION 65 WARNING: Batteries, 1. Remove the battery (1), battery acid (2), funnel (3)
battery posts, terminals and related accessories contain and cap (4) from the box.
lead and lead compounds, and other chemicals known
to the State of California to cause cancer and birth
defects or other reproductive harm. WASH HANDS
AFTER HANDLING.Battery electrolyte is poisonous. It
contains acid! Serious burns can result from contact
with the skin, eyes, or clothing.
ANTIDOTE
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
a physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using
in closed space. Always shield eyes when working near
batteries.
Keep out of reach of children. 2. Remove the protective strip from the top of the
battery. Insert the battery electrolyte funnel into the
filler holes.
IMPORTANT
3. Carefully press the battery electrolyte pack onto the
DO NOT activate Youth ATV batteries unless they will funnel. The funnel will puncture the pack seals,
be put into service within 30 days of activation. releasing electrolyte into the battery. Allow the pack
to drain for 20 minutes, periodically tapping the sides
Youth ATVs have a Low Maintenance style battery. Do to release any air-lock or bubbles that may be
not remove the battery cap strip to check acid level or present.
add water once the battery have been activated. Perform 4. Properly dispose of the battery electrolyte pack. Let
8
the proper battery tests and charge or replace the battery battery set with the vent cap strip off for 30 minutes
as required. to allow full absorption of the electrolyte. After 30
New batteries must be fully charged before use or minutes, install the battery seal strip onto the battery.
battery life will be significantly reduced (10-30% of the
5. Charge the battery initially for 3 to 5 hours using
battery’s full potential).
Christie Charger PA-37453 or a charger with an
NOTE output capable of 1/10th the battery’s amp-hour
rating.
DO NOT use a constant high-amperage battery charger
to charge this style of battery. Use a low-amperage
charger capable of charging voltage that is 1/10 of the
battery amp-hour rating.

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BATTERY REMOVAL - 50CC 5. Remove the battery from the ATV.

WARNING
Improperly connecting or disconnecting battery cables
can result in an explosion and cause serious injury or
death. When removing the battery, always disconnect
the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.

To remove the battery:

1. Remove the (3) bolts securing the battery bracket to
the frame and remove the battery and bracket from
the frame.

BATTERY REMOVAL - 90CC

WARNING
Improperly connecting or disconnecting battery cables
can result in an explosion and cause serious injury or
death. When removing the battery, always disconnect
the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
2. Remove the (2) nuts securing the hold-down strap
on the battery. To remove the battery:
1. Remove the seat to access the battery.

2. Disconnect the hold-down strap securing the battery

3. Disconnect the black negative (-) battery cable first.
in position.
4. Disconnect the red positive (+) battery cable next.
3. Disconnect the black negative (-) battery cable first.
4. Disconnect the red positive (+) battery cable last.
5. Lift the battery out of the ATV.

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BATTERY CLEANING BATTERY LOAD TEST

Keep the battery terminals and connections free of
corrosion. If cleaning is necessary, remove the corrosion CAUTION
with a stiff wire brush. Wash with a solution of one Remove the spark plug high tension lead and connect
tablespoon baking soda and one cup water. Rinse well securely to engine ground before proceeding.
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly. A battery may indicate a full charge condition in the
battery voltage test and the specific gravity test, but still
BATTERY INSTALLATION may not have the storage capacity necessary to properly
1. Place the fully charged battery in its holder. function in the electrical system.
For this reason, a battery capacity or load test should be
2. Attach the hold-down strap(s). conducted whenever poor battery performance is
3. Connect and tighten the red positive (+) cable first. suspected. To perform this test:
4. Connect and tighten the black negative (-) cable last. 1. Connect a multi-tester to the battery in the same
manner as was done in the battery voltage test. The
5. Torque the battery terminal bolts to 3.5 ft. lbs. (4.7 reading should be 12.4 volts or greater.
Nm)
2. Engage the electric starter and view the registered
6. Verify that the cables are properly routed. battery voltage while cranking the engine. Continue
the test for 15 seconds. During this cranking period,
NOTE the observed voltage should not drop below 9.5
When installing a new battery, make sure it's fully volts.
charged prior to its initial use. Using a new battery that 3. If the beginning voltage is 12.6 or higher and the
has not been fully charged can damage the battery and cranking voltage drops below 9.5 volts during the
result in a shorter life. It can also hinder vehicle test, replace the battery.
performance. If charging is necessary, use a .5 amp
battery charger.

BATTERY VOLTAGE TEST

Battery voltage should be checked with a digital multi-
tester. Readings of 12.4 or less require further battery
testing and charging. See Load Test.
8
NOTE
Batteries should be kept at or near a full charge as
possible. If the battery is stored or used in a partially
charged condition, crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.

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ELECTRICAL

BATTERY CHARGING PROCEDURE BATTERY STORAGE

Charge the battery using a charger capable of producing Whenever the vehicle is not used for a period of three
voltage 1/10th of the battery’s amp/hr rating. Example: months or more, remove the battery from the vehicle,
Youth ATV batteries have an amp/hr rating of 4.85 amps. ensure that it's fully charged, and store it out of the sun in
Do not exceed .5 amps charging voltage or damage to a cool, dry place. Check battery voltage each month
the battery will result. during storage and recharge as needed to maintain a full
Fully charged, the battery should read 12.8-13.0 Volts. charge.
After charging is complete, let the battery stand 1-2
hours and re-test the voltage. Do not overcharge the
battery!
There is no need to remove the cell cap strip or add
water for the life of the battery.

YOUTH ATV BATTERY CHARGING CHART

STATE
OF AC-
VOLTAGE CHARGE TIME
CHAR- TION
GE
FULL None
100% 12.8-13.0 V None Required
Slight
75% 12.5-12.8 V 3-6 Hours @ 0.5 A
Charge

50% 12.0-12.5V Charge 5-11 Hours @ 0.5 A

13+ Hours @ 0.5 A
25% 11.5-12.0v Charge
Check Charging
20 Hours @ 0.5 A
Less than Charge
0% Battery may be
11.5v
dead

Because of the characteristics of a sealed battery,

overcharging decreases the volume of electrolyte. The
longer the overcharge time, the greater the drop in
electrolyte, and subsequently starting power. Water
cannot be added to a sealed battery. If a sealed battery is
overcharged, it will have to self-discharge before it can
be used. Overcharging can also warp plates, making
future charging difficult. Watch charging times carefully,
or use a charger with limited charging time/current
capabilities. Polaris recommends using the Christie Multi
Battery Charger (PV-67030), available from tool provider
Bosch Automotive Service Solutions for charging
batteries. Always stop charging if the battery becomes
warm to the touch. Let it cool sufficiently before resuming
charging.

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 ELECTRICAL

STARTER SYSTEM
STARTER RELAY STARTER MOTOR SERVICE
The starter motor is a complete service part. If it is
determined that the starter motor is the failed part,
replace as needed. See the parts manual for correct part
numbers.

The starter relay consists of a simple 2-way circuit.

Power is present at the (RD) wire from the battery. Once
the switching side of the relay receives power from the
brake switch and a ground path from the starter button,
battery power is sent to the starter motor to crank the
engine.
Use the illustration below when troubleshooting a “No
Start” condition.

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ELECTRICAL

STARTER DISASSEMBLY 3. Remove magnet housing while holding the armature

and brush holder section together.
NOTE
Use only electrical contact cleaner to clean starter
motor parts. Other solvents may leave a residue or
damage internal parts and insulation.

NOTE
Some starter motors may not be serviceable.
Replacement of entire assembly may be required.
Check the parts manual for replacement part
information.

1. Disconnect the negative battery cable and starter

motor harness. Remove the (2) bolts from the starter
and pull it from the engine.

2. Remove the three screws and washers.

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 ELECTRICAL

STARTER BRUSH INSPECTION / ARMATURE TEST

REPLACEMENT 1. Inspect surface of commutator. Replace if
1. Using an Ohm meter, measure the resistance excessively worn or damaged.
between the cable terminal and the insulated brush. 2. Using a digital multi-tester, measure the resistance
The reading should be .3 ohms or less. Measure the between each of the commutator segments. The
resistance between the cable terminal and brush reading should be .3 ohms or less.
housing. Make sure the brush is not touching the
case. The reading should be infinite (no reading).
2. Remove the brush plate and brushes. Measure the
brush length and replace if worn past the service
limit.

3. Measure the resistance between each commutator

segment and the armature shaft. The reading should
be infinite. (no continuity)
MEASUREMENT
Brush LengthService Limit: .20” (5 mm)

3. Inspect the surface of the commutator for wear or

discoloration. See Armature Test.
4. Be sure that the terminal bolt insulation washer is
properly seated in the housing and the tab on the 8
brush plate engages the notch in the brush plate
housing.

4. Check commutator bars for discoloration. Bars

discolored in pairs indicate shorted coils, requiring
replacement of the starter motor.
5. Place armature in a growler. Turn growler on and
position a hacksaw blade or feeler gauge lengthwise
1/8² (.3 cm) above armature coil laminates. Rotate
armature 360°. If hacksaw blade is drawn to
armature on any pole, the armature is shorted and
must be replaced.

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ELECTRICAL

6. Inspect the permanent magnets in starter housing. STARTER REASSEMBLY

Make sure they are not cracked or separated from 1. Place armature in field magnet casing.
housing.
2. Inspect and replace the O-rings if damaged.
CAUTION
3. Install case sealing O-ring. Make sure O-ring is in
Use care when handling the starter housing. Do not good condition and not twisted on the case.
drop or strike the housing, as magnet damage is Lubricate the ends of the armature shaft and oil seal
possible. If the magnets are damaged, the starter must with a light film of grease, and install housing.
be replaced.
4. Install brush housing onto the armature, pushing
back brushes while installing armature shaft.
5. Reinstall starter motor housing screws and washers.
Make sure O-rings are in good condition and seated
in groove. Tighten sufficiently.
6. Reinstall the starter motor to the engine.

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 ELECTRICAL

VOLTAGE DROP TEST STARTER SYSTEM TROUBLESHOOTING

The Voltage Drop Test is used to test for bad Starter Motor Does Not Turn
connections. When performing the test, you are testing
• Battery discharged - low specific gravity
the amount of voltage drop through the connection. A
• Loose or faulty battery cables or corroded connections
poor or corroded connection will appear as a high
(see Voltage Drop Tests)
voltage reading.
• Related wiring loose, disconnected, or corroded
To perform the test, place the meter on DC volts and • Poor ground connections at battery cable, starter
place the meter leads across the connection to be tested. motor or starter solenoid (see Voltage Drop Tests)
Refer to the chart on next page to perform voltage drop • Faulty starter button
tests on the starter system. • Faulty ignition switch (Do other systems function?)
• Faulty starter solenoid or starter motor
Voltage should not exceed .1 DC volts per connection • Engine problem - seized or binding (Can engine be
rotated easily with recoil starter?).
Starter Motor Turns Over Slowly
• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test below)
• Engine problem - seized or binding (Can engine be
rotated easily with recoil starter?)
• Faulty or worn brushes in starter motor
• Automatic compression release inoperative
Starter Motor Turns - Engine Does Not Rotate
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel

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ELECTRICAL

STARTER SYSTEM TESTING

Condition: Starter motor fails to turn engine.

NOTE
Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital
multitester must be used for this test.

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50cc Handlebar Removal......................................................... 6.6, 6.10
Exploded View.......................................................5.30 Brakes ..................................................................... 6.2
50cc Shocks Inspection.............................................................2.34 IX
Installation ............................................................5.18 Brakes (Front)
50cc Steering Post Nut Torque Exploded View........................................................ 6.3
Specification .........................................................5.27 Brakes {Rear}
90cc Handlebar Exploded View........................................................ 6.8
Exploded View.......................................................5.30 Bumper Removal
90cc Shocks Outlaw 50 .............................................................. 5.5
Installation ............................................................5.18 Outlaw 90 .............................................................5.10
90cc Steering Post Nut Torque Bumper/Rack Removal
Specification .........................................................5.28 Sportsman 90 ........................................................5.15

A C
A-arms Cam Chain
Exploded View.......................................................5.22 Tensioner Blade .....................................................3.32
Installation ............................................................5.22 Cam Chain Tensioner
Adjustment Inspection.............................................................3.20
Front Brake ...........................................................2.35 Installation ............................................................3.46
Rear Brake ...........................................................2.36 Removal...............................................................3.19
TRS switch ............................................................ 8.6 Camshaft
Adjustments Installation ............................................................3.44
Brake Lever ..........................................................2.34 Removal...............................................................3.22
Air Box Specifications ........................................................3.22
Sediment Tube ......................................................2.17 Carburetion
Air Filter Specifications ......................................................... 4.2
Replacement.........................................................2.17 Carburetor
Alternator 50cc Mikuni........................................................... 4.11
Testing .................................................................8.18 Air/Fuel Mixture Ratio............................................... 4.5
Armature Assembly .............................................................4.15
Testing .................................................................8.25 Cleaning...............................................................4.13
Disassembly ......................................................... 4.11
Draining ...............................................................2.16
B Float Bowl Draining.................................................4.10
Float Height Adjustment...........................................4.15
Battery Float System .......................................................... 4.4
50cc ....................................................................2.26 Idle Speed Adjustment ............................................2.14
Charging ..............................................................8.22 Inspection.............................................................4.14
Cleaning....................................................... 2.27, 8.21 Jet Needle ............................................................. 4.5
Installation .................................................... 2.27, 8.21 Jet Needle / Needle Jet............................................. 4.8
Load Test .............................................................8.21 Main Jet ................................................................ 4.7
Maintenance ................................................. 2.26, 8.19 Main System .......................................................... 4.9
New Activation.......................................................8.19 Needle and Seat Leak Test.......................................4.16
Removal....................................................... 2.26–2.27 Needle Jet ............................................................. 4.6
Storage ........................................................ 2.27, 8.22 Operation .............................................................. 4.4
Voltage Test ..........................................................8.21 Pilot Air Screw .......................................................2.14
Battery (50cc) Pilot Jet ................................................................. 4.5
Removal...............................................................8.20 Pilot System ........................................................... 4.7
Battery (90cc) Removal...............................................................4.10
Removal...............................................................8.20 Slide Cutaway ........................................................ 4.8
Body Exploded View Throttle Opening vs. Fuel Flow ................................... 4.6
Outlaw 50 .............................................................. 5.7 Throttle Slide .......................................................... 4.6
Outlaw 90 ............................................................. 5.11 Carburetor,
Sportsman 90 ........................................................5.15 90cc Keihin ...........................................................4.12
Body Removal Disassembly .........................................................4.12
Outlaw 50 .............................................................. 5.4 Carburetor, Function ................................................... 4.3
Brake CDI Output
Assembly {Front}..................................................... 6.7 Testing .................................................................8.14
Drum Backing Plate ................................................. 6.5 Charging System
Brake Drum Backing Plate Testing .................................................................8.16
Front Brake ............................................................ 6.5 Choke Cable
Brake Lever Adjustments ............................................2.34 Adjustment ...........................................................2.13
Brake Lever Switches.................................................. 8.4 Clutch Cover
Brake Shoe Installation ............................................................. 7.6
Inspection.............................................................2.36 Removal................................................................ 7.5

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Control Arm Drying Procedure
Exploded View.......................................................5.20 CVT ..................................................................... 7.3
Conversion Table ....................................................... 1.9
Crankcase
Assembly .............................................................3.41 E
Disassembly ................................................. 3.37, 3.39
Crankcase Oil Strainer Electrical
Inspection.............................................................3.40 Brake Lever Switches............................................... 8.4
Crankshaft Electrical Service Notes ............................................... 8.3
Inspection.............................................................3.40 Electrical Special tools................................................. 8.3
Removal...............................................................3.39 Engine
CVT Accessible Components ..........................................3.12
Clutch Cover Installation ........................................... 7.6 Breather/Separator .................................................3.15
Clutch Cover Removal.............................................. 7.5 Camshaft..............................................................3.22
Drive Belt Installation ............................................... 7.6 Combustion Chamber .............................................3.24
Drive Belt Removal .................................................. 7.5 Compression Test ..................................................2.20
Drive Clutch Operation ............................................. 7.2 Cylinder Head.........................................3.24–3.25, 3.31
Driven Assembly ....................................................3.58 Cylinder Head Removal ...........................................3.20
Driven Clutch Assembly...........................................7.14 Cylinder Removal ...................................................3.32
Driven Clutch Disassembly....................................... 7.11 Installation Notes ...................................................3.14
Driven Clutch Operation............................................ 7.2 Lubrication Requirements ........................................3.15
Drying Procedure .................................................... 7.3 Oil and Filter Change ..............................................2.19
Maintenance / Inspection .......................................... 7.2 Oil Level ...............................................................2.18
Overheating / Diagnosis............................................ 7.4 Piston Removal......................................................3.33
CVT Drain Plug.........................................................2.21 Piston Ring Installation ............................................3.41
CVT Drying ..............................................................2.21 Removal...............................................................3.13
CVT, Operation Overview............................................. 7.2 Rocker Arm...........................................................3.21
Cylinder Service Data .......................................................... 3.4
Inspection.............................................................3.33 Special Tools .......................................................... 3.3
Installation ............................................................3.43 Top Dead Center ....................................................3.18
Removal...............................................................3.32 Top End Disassembly..............................................3.19
Cylinder Head Engine / Frame Ground
Assembly .............................................................3.31 Inspection.............................................................2.29
Disassembly .........................................................3.25 Engine Breather ........................................................3.15
Installation ............................................................3.44 Engine Breather Replacement .....................................3.15
Torque .................................................................3.44 Engine Designation Numbers........................................ 1.3
Cylinder Head Removal ..............................................3.20 Engine Mounts
Cylinder Honing ........................................................3.34 Inspection.............................................................2.20
Engine,
Exploded Views ...................................................... 3.8
D Exhaust
Cleaning...............................................................2.22
Daytime Running Lamps Exploded View
Replacement.......................................................... 8.7 50cc Handlebar .....................................................5.30
Daytime Running Light {DRL} 90cc Handlebar .....................................................5.30
Test ...................................................................... 8.7 A-arms.................................................................5.22
Decal Replacement ...................................................5.31 Air Cleaner............................................................4.20
Decimal Equivalent Chart............................................ 1.11 Brakes (Front) ........................................................ 6.3
Disassembly ............................................................3.61 Brakes {Rear} ......................................................... 6.8
Starter .................................................................8.24 Steering Post Assembly................................... 5.27–5.28
Drive Belt Exploded Views
Installation ............................................................. 7.6 Engine .................................................................. 3.8
Removal................................................................ 7.5
Drive Chain
50cc Inspection......................................................2.24 F
Adjustment ...........................................................2.25
Inspection.............................................................2.24 Fastener Torque Table
Drive Clutch Body/Suspension/Steering ........................................ 5.3
Assembly .............................................................. 7.9 Flywheel Inspection
Disassembly and Inspection ...................................... 7.7 Removal...............................................................3.37
Drive Clutch Operation Footwell Removal
CVT ..................................................................... 7.2 Outlaw 50 .............................................................. 5.5
Driven Clutch Assembly..............................................7.14 Outlaw 90 .............................................................. 5.9
Driven Clutch Disassembly Sportsman 90 ........................................................5.13
CVT .................................................................... 7.11 Front Brake
Driven Clutch Operation Adjustments ..........................................................2.35
CVT ..................................................................... 7.2 Assembly .............................................................. 6.7

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 Wheel Bearing Inspection ......................................... 6.4 Fuel Lines.............................................................2.14
Front Cab Removal Piston ..................................................................3.35
Outlaw 90 .............................................................5.10 Pre-ride................................................................. 2.8 IX
Sportsman 90 ........................................................5.13 Rear Suspension ...................................................2.33
Front Suspension Sprocket...............................................................2.25
Inspection.............................................................2.33 Steering ...............................................................2.30
Fuel Delivery ............................................................. 4.9 Tie Rod ................................................................2.31
Fuel Filter Tires ....................................................................2.39
Inspection.............................................................2.14 Transmission.........................................................3.49
Fuel Lines Wheel ..................................................................2.37
Inspection.............................................................2.14 Installation
Fuel System 50cc Shocks..........................................................5.18
Warnings ..............................................................2.10 90cc Shocks..........................................................5.18
Fuel Tank Battery ......................................................... 2.27, 8.21
Removal...............................................................4.17 Camshaft..............................................................3.44
Fuel Valve Cylinder ...............................................................3.43
Layout .................................................................4.19 Cylinder Head........................................................3.44
Location ....................................................... 2.15, 4.17 Piston ..................................................................3.42
Service ................................................................4.18 Tensioner Blade .....................................................3.42
Fuse Wheel ..................................................................2.38
Location ...............................................................8.17 Installation Notes
Main ....................................................................2.28 Engine .................................................................3.14
Fusible Link
Location ...............................................................8.17
K
G Key Switch................................................................ 8.6
Keys
General Information Replacement.......................................................... 1.7
Outlaw 50 .............................................................. 1.4 Kick Start.................................................................3.61
Outlaw 90 / Sportsman 90 ......................................... 1.6 Assembly .............................................................3.62
Operation .............................................................. 2.9

H
Heat Shield ..............................................................3.48
L
Heat shield replacement .............................................3.48 Lubrication Change
Transmission.........................................................2.24
Lubrication Level
I Transmission.........................................................2.23

Idle Speed
Adjustment ...........................................................2.14 M
Ignition Coil
Testing .................................................................8.14 Maintenance
Ignition System Battery ......................................................... 2.26, 8.19
Testing .................................................................8.13 Steering ...............................................................2.30
Troubleshooting .....................................................8.12 Maintenance Chart ..................................................... 2.3
Ignition Timing 50 - 300 Hours ........................................................ 2.5
Specification .........................................................2.29 Pre-Ride - 40 Hours ................................................. 2.4
Indicator Lamp Maintenance References ............................................. 2.7
Replacement.......................................................... 8.9 Measurement
Indicator Light Brake Pad....................................................... 6.6, 6.10
Replacement.........................................................5.17 Throttle Release Swtich {TRS} ................................... 8.5
Inspection Miscellaneous Information............................................ 1.7
Brake Shoe ...........................................................2.36 Model Number ........................................................... 1.2
Brakes .................................................................2.34 Model Number Designation .......................................... 1.2
Camshaft..............................................................3.22 Model Overview ................................................... 1.4–1.5
Crankcase Oil Strainer ............................................3.40
Crankshaft ............................................................3.40
Cylinder Head........................................................3.24 O
Drive Chain ...........................................................2.24
Drive Clutch ........................................................... 7.7 Oil and Filter Change
Engine / Frame Ground ...........................................2.29 Engine .................................................................2.19
Engine Mounts ......................................................2.20 Oil Flow Diagram....................................................... 3.11
Flywheel...............................................................3.37 Oil Pump
Front Suspension ...................................................2.33 Removal...............................................................3.38

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Operation Side Panel Removal
Carburetor ............................................................. 4.4 Outlaw 90 .............................................................. 5.9
Outlaw 50 ................................................................. 1.4 Sportsman 90 ........................................................5.12
Body Exploded View ................................................ 5.7 Spark Plug
Body Removal ........................................................ 5.4 Inspection.............................................................2.29
Bumper Removal .................................................... 5.5 Recommended Type ...............................................2.29
Footwell Removal.................................................... 5.5 Special Tools ............................................................. 1.8
Outlaw 90 ................................................................. 1.5 Electrical ............................................................... 8.3
Body Exploded View ............................................... 5.11 Engine .................................................................. 3.3
Bumper Removal ...................................................5.10 Suspension............................................................ 5.3
Footwell Removal.................................................... 5.9 Special Tools, Fuel System........................................... 4.2
Front Cab Removal.................................................5.10 Specification
Rear Cab Removal .................................................. 5.8 50cc Steering Post Nut Torque ..................................5.27
Side Panel Removal ................................................ 5.9 90cc Steering Post Nut Torque ..................................5.28
Axle Nut Torque .....................................................6.10
Body Mount Bolt Torque.......................................5.5, 5.9
P Brake Component Torque Values................................ 6.2
Cam Chain Tensioner Bolt Torque ..............................3.46
Paint Codes .............................................................. 1.7 Cam Chain Tensioner Cap Torque..............................3.46
Pilot Air Screw ..........................................................2.14 Carburetor Air Screw Setting ....................................4.15
Piston Compression Spring Length ..................................... 7.11
Inspection.............................................................3.35 Cylinder Head Warp................................................3.24
Installation ............................................................3.42 Cylinder Taper .......................................................3.33
Removal...............................................................3.33 Cylinder Warp........................................................3.33
Piston Identification ...................................................3.12 Drive Belt Width ..................................................... 7.11
Piston Ring Drive Clutch Nut Torque ............................................ 7.9
Installation ............................................................3.41 Driven Assembly Nut Torque............................. 3.58, 7.14
Specification .........................................................3.36 Driven Clutch Nut Torque ................................. 3.58, 7.14
Polaris Lubricants and Maintenance Products .................. 2.6 Driven Clutch Wear Limits ........................................ 7.11
Pre-ride Inspection ..................................................... 2.8 Engine
Publication Numbers ................................................... 1.7 Cylinder Head Warp.............................................3.24
Pulser Coil Output Engine Compression...............................................2.20
Testing .................................................................8.15 Engine Drain Plug Torque ........................................2.19
Engine Lubrication Requirements ..............................3.15
Engine Oil Type .....................................................2.18
R Front Bumper Bolt Torque .................................. 5.5, 5.10
Fuel Tank Bolt Torque..............................................4.17
Rear Brake Hub Nut Torque......................................................2.37
Adjustments ..........................................................2.36 Idle Speed ............................................................2.14
Rear Cab Removal Ignition Timing .......................................................2.29
Outlaw 90 .............................................................. 5.8 Kick Start Cover Bolt Torque .....................................3.62
Sportsman 90 ........................................................5.12 Piston Ring Installed Gap .........................................3.36
Rear Suspension Shift Detent 110cc Hex Bolt Torque ............................3.55
Inspection.............................................................2.33 Shock Mounting Torque ...........................................5.19
Rectifier ..................................................................8.17 Spark Plug Torque ..................................................2.29
Regulator ................................................................8.17 Tensioner Blade Bolt Torque .....................................3.42
Removal Tie Rod Nut Torque.................................................5.29
Battery .................................................................2.27 Tire Wear .............................................................2.39
Battery (50cc) ........................................................8.20 Transmission Cover Bolt Torque ................................3.55
Battery (90cc) ........................................................8.20 Transmission Lubrication Requirements ......................3.15
Rocker Arm Transmission Sprocket Nut Torque.............................3.55
Disassembly and Inspection .....................................3.21 Valve Clearance.....................................................2.20
RPM Limiter Wheel Nut Torque............................................. 2.37, 6.7
Specifications ........................................................8.14 Specifications
Brakes .................................................................. 6.2
Engine Service Data ................................................ 3.4
S RPM Limiter ..........................................................8.14
Tire Pressure.........................................................2.39
Sediment Tube Transmission Lubrication .........................................2.23
Air Box .................................................................2.17 Specifications, General................................................ 1.4
Service Speed Control ..........................................................2.10
Fuel Valve.............................................................4.18 Throttle Stop ......................................................... 2.11
Service Notes Speed Limiter ...........................................................2.10
Battery Maintenance ...............................................2.26 Sportsman 90 ............................................................ 1.5
Shock Removal Body Exploded View ...............................................5.15
Front ...................................................................5.18 Bumper/Rack Removal............................................5.15
Rear ....................................................................5.19 Footwell Removal...................................................5.13

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 Front Cab Removal.................................................5.13 Inspection.............................................................2.31
Rear Cab Removal .................................................5.12 Removal...............................................................5.29
Side Panel Removal ...............................................5.12 Tire Pressure IX
Spring Adjustment .....................................................2.33 Specifications ........................................................2.39
Sprocket Tires
Inspection.............................................................2.25 Inspection.............................................................2.39
Standard Torque Specifications ..................................... 2.9 Toe Alignment ..........................................................2.32
Starter Torque ..................................................................... 6.2
Assembly .............................................................8.26 Transmission
Disassembly .........................................................8.24 Disassembly .........................................................3.49
Relay...................................................................8.23 Lubricant Change ...................................................2.24
Starter Brush Lubricant Level ......................................................2.23
Inspection.............................................................8.25 Lubrication............................................................2.23
Replacement.........................................................8.25 Lubrication Requirements ........................................3.15
Starter Motor Service .................................................8.23 Shifter Gear Orientation ...........................................3.52
Starter System Transmission Switch
Testing .................................................................8.28 Inspection............................................................. 8.11
Troubleshooting .....................................................8.27 Installation ............................................................ 8.11
Stator Removal............................................................... 8.11
Testing .................................................................8.18 Testing ................................................................. 8.11
Steering Troubleshooting
Inspection and Maintenance .....................................2.30 Engine .................................................................3.65
Toe Adjustment ......................................................2.32 Ignition System ......................................................8.12
Wheel Alignment ....................................................2.31 Spark Plug Fouling .................................................3.65
Steering Post Assembly Starter System.......................................................8.27
Exploded View............................................... 5.27–5.28 TRS Operation.................................................... 2.12, 8.5
Storage TRS switch
Battery .................................................................2.27 Adjustment ............................................................ 8.6
Suspension TRS Switch Adjustment ..............................................2.13
Special Tools .......................................................... 5.3
Suspension,
Spring Adjustment ..................................................2.33 U
Swing Arm
Assembly .............................................................6.10 Unit Serial Number and Engine Number Location .............. 1.3
Switch
LH........................................................................ 8.6
V
T Valve
Inspection.............................................................3.26
Tail Light Lamp Valve ................................................................3.26
Replacement.......................................................... 8.8 Seat Reconditioning................................................3.28
Tap / Drill Sizes {Metric} ..............................................1.10 Valve Adjustment ......................................................2.20
Tap / Drill Sizes {SAE} ................................................1.10 Valve Sealing
Tensioner Blade ........................................................3.32 Test .....................................................................3.31
Installation ............................................................3.42 Valve Sealing .....................................................3.31
Test Vehicle Identification
Daytime Running Lights............................................ 8.7 Model Number Designation ....................................... 1.2
Tether Switch ......................................................... 8.4 Vehicle Identification Number........................................ 1.2
Testing Vehicle Information
Alternator .............................................................8.18 Model Number ........................................................ 1.2
Armature ..............................................................8.25 Vent Lines
CDI Output............................................................8.14 Inspection.............................................................2.14
Charging System....................................................8.16 Vent System.............................................................. 4.9
Ignition Coil ...........................................................8.14 VIN ......................................................................... 1.2
Ignition System ......................................................8.13 Voltage Drop Test ......................................................8.27
Pulser Coil Output ..................................................8.15
Starter System.......................................................8.28
Stator ..................................................................8.18
Tether Switch
W
Test ...................................................................... 8.4 Warnings
Throttle Release Swtich {TRS} ...................................... 8.5 Fuel System ..........................................................2.10
Throttle Relese Swtich (TRS) .......................................2.12 Wheel
Throttle Stop Inspection.............................................................2.37
Speed Control ....................................................... 2.11 Installation ............................................................2.38
Tie Rod Removal...............................................................2.37
Adjustment ...........................................................5.29 Wheel Alignment

9928505 R01 - 2013-2018 Outlaw 50 / 2013-2016 Outlaw 90 Service Manual

© Copyright Polaris Industries Inc. IX.5
 Steering ...............................................................2.31
Wheel Bearing Inspection
Front Brake ............................................................ 6.4
Wheel Nut Torque
Specification .........................................................2.37
Wiring Breakdown
Break Lever Switches............................................... 8.4
Lights ................................................................... 8.7
Wiring Diagram
Youth 50 / 90 ........................................................... 29

Y
Youth 50 / 90
Wiring Diagram ........................................................ 29

9928505 R01 - 2013-2018 Outlaw 50 / 2013-2016 Outlaw 90 Service Manual

IX.6 © Copyright Polaris Industries Inc.