Polaris 2007 ATV Service Manual – Predator 50, Outlaw 90, Sportsman 90 (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.

PDF Search, Bookmarks, and Wiring Detail

Search and diagram detail: The main service text is searchable, and embedded bookmarks lead to all eight chapters, many subsections, and the first wiring diagram. Small wiring labels are legible after rotating and zooming in. The wiring labels and parts of the ignition and starter flowcharts are unavailable through text search.

The download is one printable English PDF with 170 pages, including four notes pages and both wiring-diagram pages.

ATV Service, Repair, and Diagnostics

These selected topics give a preview of the service coverage. The manual also includes spark arrestor cleaning and electric and kick-start drive service.

• 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, electronic throttle control and tether-switch checks, starter-system troubleshooting, and model-specific wiring diagrams.
• Maintenance references: Periodic service and lubrication charts, oil-change procedures, fluid capacities, component torque specifications, and engine wear limits.

The manual is suited to technicians familiar with precision engine measurement and electrical testing. Polaris specifies a trained, certified Polaris Master Service Dealer technician for CVT maintenance and repair, with factory-authorized tools and procedures for CVT disassembly or repair.

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 serviced 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 procedures before opening the carburetor.

Float-height adjustment and needle-and-seat leak testing 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, and shift forks. The transmission section identifies the retaining snap ring that must be removed before pressing the sealed output-shaft bearing out of the cover.

Clutch service covers drive rollers, sheave bushings, driven friction shoes, springs, and belt wear. The CVT Air Duct System view supports overheating diagnosis on the 90cc models. The manual also covers water-ingestion checks and CVT drying.

Steering, Suspension, and Drum Brakes

Body-removal instructions differ by model and include the Sportsman’s racks. Separate control-arm and A-arm drawings and steering assembly exploded views show the chassis differences.

Brake procedures cover shoes, cams, seals, wheel bearings, and cable and lever adjustment. The tie-rod cautions explain how misaligned rod ends can bind and break. 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 help isolate faults across the tether, electronic throttle control (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. The manual calls for starter replacement if the housing magnets are damaged.

Wiring diagrams provide wire-color and connector-termination references for the Predator circuit and the shared Outlaw/Sportsman circuit.

A Preview of Valve-Clearance and Belt-Wear Data

The valve-clearance procedure specifies .002 in. (.06 mm) for both intake and exhaust at top dead center on the compression stroke.

The CVT inspection section gives a drive-belt width service limit of .626 in. (15.9 mm), alongside separate checks for spring length and friction-shoe wear.