2007 Polaris Predator 50, Outlaw 90, Sportsman 90 ATV Service Manual (P/N 9920848)

This Polaris factory service manual (P/N 9920848) covers the 2007 Predator 50, Outlaw 90, and Sportsman 90 youth ATVs, from scheduled maintenance through internal engine and transmission repair.

• Engine repair: Top-end disassembly, cylinder-head and camshaft inspection, valve-seat reconditioning, piston installation, crankcase service, and cam-chain timing.

• Fuel system: Separate Mikuni and Keihin carburetor procedures, float-height and pilot-air-screw adjustments, needle-and-seat leak testing, and fuel-valve service.

• Transmission and CVT: Gearcase disassembly, shaft and shift-fork inspection, drive and driven clutch service, belt inspection, and overheating diagnosis.

• Chassis and brakes: Model-specific body removal, steering and suspension service, wheel alignment, and front and rear drum-brake repair.

• Electrical diagnosis: Ignition and charging tests, ETC and tether-switch checks, starter-system troubleshooting, and model-specific wiring diagrams.

• Maintenance references: Periodic service and lubrication charts, oil-change procedures, fluid-capacity data, component torque specifications, and engine wear limits.

Suited to technicians familiar with precision engine measurement and electrical testing; the CVT chapter specifically requires a trained, certified Polaris Master Service Dealer technician.

Engine Repair and Inspection

Cylinder head removal, rocker-arm and camshaft inspection, piston installation, and crankcase separation are documented with inspection limits and assembly illustrations. The Oil Flow Diagram traces pressure lubrication, splash lubrication, and the breather circuit.

Valve-seat reconditioning is a general outline that assumes proper cutting equipment and cylinder-head experience. The crankshaft is treated as a replacement assembly.

The piston-installation cautions explain how reused or deformed circlips can lose radial tension and cause severe engine damage.

Mikuni and Keihin Carburetor Service

The Predator uses a Mikuni VM12H; the Outlaw and Sportsman use a Keihin PTE16. Separate disassembly sections and carburetion charts help identify the correct jets, needle settings, and service details before a carburetor is opened.

Float-height adjustment and the needle-and-seat leak test accompany pilot-air-screw adjustment and air-intake service. Polaris assigns pilot-circuit cleaning to a certified repair shop.

Transmission and Clutch Inspection

Transmission procedures distinguish the forward-only Predator from the forward/neutral/reverse models. Internal inspection covers bearings, gear dogs, shift forks, and the output-shaft bearing's retaining snap ring.

Clutch service examines drive rollers, sheave bushings, driven friction shoes, springs, and belt wear. The CVT Air Duct System view applies to the 90cc models and supports overheating diagnosis; water-ingestion checks and drying procedures are also covered.

Steering, Suspension, and Drum Brakes

Body-removal instructions differ by model, including the Sportsman's racks. Separate control-arm and A-arm drawings, plus Steering Assembly Exploded Views, clarify the chassis differences.

Brake procedures cover shoes, cams, seals, wheel bearings, and cable and lever adjustment. Tie-rod cautions explain how incorrect rod-end positioning can restrict pivoting and lead to breakage.

Support the ATV securely during wheel and suspension work, and use eye and face protection around spring-loaded components.

Ignition, Charging, and Starter Diagnosis

The Key Switch Continuity Chart and Ignition System Testing flowchart support fault isolation across the tether, ETC, CDI, and transmission-switch circuits. Charging tests cover the stator, regulator/rectifier, and battery.

Ignition timing is CDI-controlled and nonadjustable. Starter coverage includes relay diagnosis, voltage-drop testing, brush inspection, armature testing, and reassembly; some starter motors require complete replacement.

The wiring diagrams include wire-color and connector-termination references for tracing the Predator circuit and the combined Outlaw/Sportsman circuit.

A Preview of Valve-Clearance and Belt-Wear Data

These are a few examples of the adjustment and wear data in this manual.

The valve-clearance section specifies .002 in. (.06 mm) for both intake and exhaust at TDC on the compression stroke. CVT inspection gives a drive-belt width service limit of .626 in. (15.9 mm), alongside separate checks for spring length and friction-shoe wear.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram detail: Main service text supports PDF searches, with embedded bookmarks for chapters and many subsections. Wiring-diagram lettering and parts of the ignition and starter flowcharts are not searchable. Small wiring labels are legible when enlarged and viewed in the correct orientation.

One printable PDF download contains 170 pages across eight chapters and the wiring diagrams. The total already includes four notes pages and both wiring-diagram pages.