POLARIS ATV 2004 SPORTSMAN 90 PREDATOR 50/90 Repair Manual [IMPROVED]

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GENERAL INFORMATION

MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification

A 04 EA 05 CA
Basic Chassis Designation

Year Designation

Emissions & Model Option Engine Designation

VIN IDENTIFICATION
World Mfg. ID

Vehicle Descriptor

Vehicle Identifier

1 2 R F

3 3

4 E

5 A

6 0

7 5

8 C

9 10 11 12 * 4 T 0

13 14 15 16 17 0 0 0 0 0
Individual Serial No. * This could be either a number or a letter

Body Style

Model Emissions Year Engine Check Digit Plant No. Powertrain

SERIAL NUMBER LOCATIONS
Whenever corresponding about an engine, be sure to refer to the engine serial number. This information can be found stamped on the transmission section located by the transmission oil fill plug(A). The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the front of the frame (B).

B A Front

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GENERAL INFORMATION

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2004 YOUTH MODEL ATVS

PREDATOR 50

SPORTSMAN 90

PREDATOR 90
NOTE: Model colors may vary.

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GENERAL INFORMATION
MODEL: . . . . . . . . . . 2004 PREDATOR 50 MODEL NUMBER: . A04KA05CA ENGINE MODEL: . . AR03 Engine
Platform Engine Model Number Engine Displacement Number of Cylinders Bore & Stroke (mm) Compression Ratio Compression Pressure Engine Idle Speed Engine Max Operating Rpm Cooling System Oil Warning Lubrication Oil Requirements / Capacity Exhaust System 2-Stroke Horizontal AR03-01 49.3 cc 1 1.58x1.54 / 40x39.2 mm 7.2:1 110 PSI / 7.8 kgf/cm2 1200 RPM ± 200 4 ft.lbs / 5.4 Nm Torque @ 6000 RPM Air cooled Low Oil Indicator Oil Injection Polaris 2-cycle oil 20 oz / .6 Liter Single pipe

Drivetrain
Transmission Type Transmission Capacity / Type Gear Ratio / Final Drive Clutch Type Belt Integrated - Fwd only 10oz. / 296ml Polaris Angle Drive Fluid 15/35 - #428 Chain 58P Automatic C.V.T. System 0450239

Steering / Suspension
Front Suspension Front Travel Rear Suspension Rear Travel Shock Preload Adjustment Front / Rear Turning Radius Toe Out LH/RH control arm w/shock 3 (7.62cm) Single Shock/Swing Arm 3 (7.62cm) Front - Non adjustable Rear - Cam-style 60 / 152 cm 1/8-1/4- in / 3- mm -6

Carburetion
Carburetor model Main Jet Pilot Jet Pilot Air Jet Jet Needle - Clip Position Needle/Seat Pilot Screw Float Height Fuel Delivery Fuel Capacity / Requirement Sunworld H68K 75 30 2.5 H68A-3 1.2mm Viton 3/4 ± 1/4 Parallel to surface ± 1.0 mm Gravity Feed 1 Gallon / 3.8 Liters 87 Octane (minimum) 89 Oxygenated

Wheels / Brakes
Wheel Size / Pattern - Front Wheel Size / Pattern - Rear Front Tire Model / Size Rear Tire Model / Size Recommended Air Pressure Brake - Front Brake - Rear 16x8-7 - 4/110mm 16x8-7 - 4/110mm 16x8-7 16x8-7 Front - 2 psi / Rear - 2 psi Drum Drum

General Weights / Measurements
Overall Dimensions LxWxH Seat Height Dry Weight Rider Capacity / Max Weight Wheel Base Ground Clearance 48x31.5x28 122x80x71cm 22.5 / 57 cm 185 lbs. / 84 kg 90 lbs. / 40.8 kg 33 / 84 cm 4 / 8 cm

Electrical
Alternator Output Voltage Regulator Lights : Brake Tail Low Oil Ignition System Ignition Timing Spark plug / Gap Battery / Model / Amp Hr Circuit Breakers Starting Instrument Cluster 70 Watts @ 4000 RPM 14.5 VDC/5.5 A @ 4000 RPM 18 watts 8.26 watts 1 watt CDI Ignition 17° @ 5000 RPM BPR7HS/ .036 in. / 0.9 mm Low Maintenance GTX5L-BS, 4.85 amp 7.5 Amp main fuse Electric/Kick Start N/A

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