2004 Polaris Predator 50/90, Sportsman 90 Service Manual

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Covers: 2004 Polaris Predator 50, Predator 90, Sportsman 90
Pages: 103
Format: PDF
Compatibility: Windows/Mac/Tablet

This downloadable service manual contains instructions and technical information to maintain and repair your 2004 Polaris Predator 50/90 or Sportsman 90 ATV. This is the same manual technicians use to diagnose and repair your ATV. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, the service manual provides the most accurate information to perform the job. The bookmarks panel in this manual makes it easy to quickly navigate chapters and sub-chapters.

Topics:

• 2004 Youth Models
• Specifications
• Publication Numbers
• Paint Codes
• Inspection Schedule
• Standard Torque Specifications
• Special Tools
• Lubricant and Maintenance Products
• 2004 Speed Limiter System Overview
• Vehicle Inspection/Adjustments
• Transmission Lubrication
• Throttle Operation / Idle — Air Screw Adjust
• Throttle Cable / ETC Adjustments
• Oil Pump Adjustment / Bleeding
• Oil Pump Troubleshooting
• Fuel System
• Compression Test
• Air Filter Service
• Spark Plug
• Wheels and Tires
• Steering / Alignment
• Glossary of Terms
• Unit of Measure Conversion Table
• Tap Drill Charts
• Decimal Equivalent Chart
• CVT Exploded View
• Special Tools
• Torque Specifications
• Engine Removal
• Engine Disassembly
• Transmission Service
• Engine Component Inspection
• Cylinder Honing
• Crankshaft Runout Inspection
• Constant Variable Transmission (CVT) Service
• Engine Reassembly & Installation
• Kick Start and Spring Installation
• Starter Drive One Way Clutch
• Engine Troubleshooting
• Carburetor Exploded View
• Carburetor Special Tools
• Carburetor Specifications
• Optional Main Jets
• High Altitude Operation
• Carburetor Operation Overview
• Fuel Delivery
• Vent System / Float Height Setting
• Needle and Seat Leakage Test
• Oil Check Valve Pressure Test
• Carburetor Float Bowl Draining
• Troubleshooting
• Engine Mounting Exploded View
• Torque Specifications / Special Tools
• Engine Mounting
• Shocks and Springs
• Suspension A–Arms
  Steering
• Front Brake
• Rear Brake and Axle
• Fuel and Oil Tank
• Predator Cab
• Sportsman Front and Rear Cab
• Sportsman Handlebar Assembly
• Predator Handlebar Assembly
• Muffler Assembly
• Special Tools
• Electrical Service Notes
• 2004 Model Speed Limiter System
• Brake Light Bulb Replacement
• Battery Service / Terminals and Bolts
• Battery Inspection / Removal
• Battery Installation
• Open Circuit Voltage Test
• Load Test
• Off Season Storage
• Charging Procedure
• Charging System Testing
• Current Draw / Key Off Test
• Charging System Break Even Test
• Alternator Output Test
• Ignition System / Spark Plug
• Starter System Troubleshooting / Voltage Drop Test
• Starter System Diagnosis
• Starter Motor Disassembly
• Brush Inspection / Replacement
• Armature Testing
• Starter Assembly
• Electronic Throttle Control (ETC)
• Coil Tests
• Ignition System Troubleshooting
• Wiring Diagram – 50 CC Models
• Wiring Diagram – 90 CC Models