2001 Polaris 90 Service Repair Manual Download
CHAPTER 1:
GENERAL INFORMATION
Model Identification 11
Serial Number Location 11
Specifications – General 12
Publication Numbers 13
Paint Codes 13
Standard Torque Specifications 14
Lubricant and Maintenance Part Numbers 14
Torque Conversion Table 15-16
Decimal Equivalent Chart 17
Unit of Measure Conversion Table 18
Tap Drill Charts 19
Glossary of Terms 110-111
Inspection Schedule 112
Vehicle Inspection 113-115
Transmission Lubrication 116
Throttle Operation / Air Screw Adjustment 117
Idle Speed Adjustment 118
Throttle Cable Adjustment 118-119
Oil Pump Adjustment / Bleeding 120
Oil Pump Troubleshooting 121
Fuel System 122-123
Compression Test 124
Air Filter Service 124
Wheels and Tires 125-126
Alignment 127-128
2001 Polaris 90 Service Repair Manual Download
VIN IDENTIFICATION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4XA E A 0 5A* 1 P 0 0 0 0 0 0
Vehicle Descriptor Vehicle Identifier
Powertrain
Engine
Emissions Model
Year
Plant No.
Individual Serial No. Body Style
Check Digit
World Mfg. ID
- This could be either a number or a letter
ENGINE SERIAL NUMBER LOCATION
Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found stamped on the transmission section located by the transmission oil fill plug(A).
MACHINE SERIAL NUMBER LOCATION
The machine model number and serial number are important for vehicle identification. The machine the serial number is stamped on the front of the frame tube(B).
To obtain correct chain tension: Motorcycle
- Elevate rear of machine so track is off floor.
- Rotate driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever.
- Loosen adjuster bolt jam nut.
- Finger tighten adjuster bolt until it can no longer be adjusted by hand.
- Back off adjuster bolt 1/4 turn.
- Tighten jam nut while holding adjuster bolt.
- The chain is now tensioned. Release brake lever lock.
Drive Chain Tension – Chaincase cover removed
To obtain correct chain tension: - Remove drain plug (F) and drain oil into a suitable container.
Dispose of properly. - Remove the chaincase cover.
- While putting a slight reverse tension on the chain by turning brake disc as indicated by the arrow (A), there
should be approximately 1/4-3/8″ (.6-1 cm) deflection on the chain at point (B). Refer to illlustration 1. - The chain is adjusted by loosening the adjusting bolt locknut (C) and turning adjusting bolt (D) until correct
chain deflection is obtained. - Lock the adjusting bolt locknut (C) while holding a wrench on the adjusting bolt (D) to prevent it from turning.
