2006 Polaris Predator 50/90, Sportsman 90 ATV Factory Service Manual (P/N 9920234)

Factory service manual for the 2006 Polaris Predator 50, Predator 90, and Sportsman 90 youth ATVs, P/N 9920234.

• Engine repair: Engine removal and reinstallation, crankcase separation, piston and reed-valve inspection, cylinder honing, crankshaft checks, and reassembly.

• CVT and transmission: Drive and driven clutch service, primary sliding sheave inspection, separate transmission procedures for the 50 and 90 models, and kick start repair.

• Fuel and oil systems: Carburetor float adjustment, needle-and-seat leak testing, oil pump bleeding and adjustment, and lubrication charts.

• Chassis and brakes: Front and rear drum-brake service, brake lever adjustments, A-arm and swing-arm installation, drive chain adjustment, and toe alignment.

• Electrical diagnosis: Starter and charging flow charts, stator and ignition coil tests, Electronic Throttle Control operation, and reverse speed limiter testing.

• Service references: Periodic maintenance schedules, component-specific torque tables, inspection limits, and model-specific wiring diagrams.

Suited to technicians familiar with two-stroke engine measurement and electrical testing; the overhaul procedures call for measuring equipment and dedicated pullers.

Engine and Drivetrain Repair

Engine coverage distinguishes the Predator 50's AR03-01 from the AR07-01 in both 90 models. Cylinder oversize honing, piston-to-cylinder clearance checks, and crankshaft runout measurement are covered.

The connecting rod's crankshaft end is not serviceable separately; the manual specifies crankshaft assembly replacement. Engine procedures identify flywheel puller PA-45153 and crankcase/crankshaft separating tool PV-46087, with fastener data for cylinder head nuts, flywheel mounting, and intake-manifold bolts.

Separate transmission sections cover the Predator 50's reduction gears and the 90 models' shift drum, shift fork, and forward/reverse gear assembly. The CVT System Exploded View and starter one-way drive illustrations support component identification during disassembly and reassembly.

Carburetor and Oil-Injection Service

Sunworld H68K coverage explains the pilot and main circuits, throttle-slide cutaway, jet needle, and float system. A carburetor exploded view, optional-jet parts table, and fuel-flow illustrations accompany the adjustment and leak-test procedures.

High-altitude jetting and clutch changes are described as optional. The manual warns that an undersized main jet can create a lean mixture and damage the engine.

Oil-pump troubleshooting addresses delivery faults, air in the lines, and cable adjustment. Maintenance charts specify lubrication for the drive chain and front A-arms.

Brake, Steering, and Body Work

Illustrations distinguish the A-arm and spindle arrangements, and the body section separates Predator and Sportsman panel and handlebar installation. Toe-alignment methods are included; camber and caster are nonadjustable.

Steering guidance identifies incorrect tie-rod-end positioning during jam-nut tightening as a cause of restricted pivoting and possible rod-end breakage. Follow the manual's precautions for brake, throttle-control, and spring-loaded clutch work.

Starting, Charging, and Ignition Diagnostics

The Starter System Test Flow Chart and Charging System Test Flow Chart help distinguish battery, wiring, solenoid, and charging faults before component replacement. Battery activation, starter brush inspection, armature testing, and starter reassembly are covered; some starter motors require replacement as a complete assembly.

Separate Predator 50 and Predator/Sportsman 90 wiring diagrams show connector layouts, wire colors, and model-specific stator resistance references. ETC switch operation and the reverse limiter on equipped 90 models have dedicated diagnostic coverage; ignition timing is nonadjustable.

A Few Engine and Driveline Specifications

These figures are a small sample of the manual's service data. For the Predator 50, the compression-test section gives 110–130 psi at 0–1,000 ft elevation, measured during cranking with the throttle open. Intake-manifold bolt torque is 12 Nm.

For Predator 90 and Sportsman 90, the model tables specify a 480 ml transmission refill with Polaris AGL Gearcase Lube. The CVT inspection section lists a drive-belt width service limit of 0.626 in. (15.9 mm).

PDF Navigation and Page Breakdown

Search and diagram detail: Much of the manual's body text is searchable, but some tables, flow charts, and wiring labels are not. Embedded bookmarks cover the chapters and many subsections. Small wiring labels require zooming; rotating the wiring pages also makes them easier to read.

One printable, 126-page PDF in English. The total includes two wiring-diagram pages, seven notes pages, and one product-information page.