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GENERAL INFORMATION

9923074 - 2011 Youth 4-Stroke Service Manual

© Copyright 2010 Polaris Sales Inc.

SAE Tap Drill Sizes

Metric Tap Drill Sizes

Decimal Equivalents

Thread Size / Drill Size

Thread Size / Drill Size

#0-80

3/64

1/2-13

27/64

#1-64

53

1/2-20

29/64

#1-72

53

9/16-12

31/64

#2-56

51

9/16-18

33/64

#2-64

50

5/8-11

17/32

#3-48

5/64

5/8-18

37/64

#3-56

45

3/4-10

21/32

#4-40

43

3/4-16

11/16

#4-48

42

7/8-9

49/64

#5-40

38

7/8-14

13/16

#5-44

37

1-8

7/8

#6-32

36

1-12

59/64

#6-40

33

1 1/8-7

63/64

#8-32

29

1 1/8-12

1 3/64

#8-36

29

1 1/4-7

1 7/64

#10-24

24

1 1/4-12

1 11/64

#10-32

21

1 1/2-6

1 11/32

#12-24

17

1 1/2-12

1 27/64

#12-28

4.6mm

1 3/4-5

1 9/16

1/4-20

7

1 3/4-12

1 43/64

1/4-28

3

2-4 1/2

1 25/32

5/16-18

F

2-12

1 59/64

5/16-24

I

2 1/4-4 1/2

2 1/32

3/8-16

O

2 1/2-4

2 1/4

3/8-24

Q

2 3/4-4

2 1/2

7/16-14

U

3-4

2 3/4

7/16-20

25/64

Tap Size

Drill Size

Decimal 

Equivalent

Nearest 

Fraction

3x.50

#39

0.0995

3/32

3x.60

3/32

0.0937

3/32

4x.70

#30

0.1285

1/8

4x.75

1/8

0.125

1/8

5x.80

#19

0.166

11/64

5x.90

#20

0.161

5/32

6x1.00

#9

0.196

13/64

7x1.00

16/64

0.234

15/64

8x1.00

J

0.277

9/32

8x1.25

17/64

0.265

17/64

9x1.00

5/16

0.3125

5/16

9x1.25

5/16

0.3125

5/16

10x1.25

11/32

0.3437

11/32

10x1.50

R

0.339

11/32

11x1.50

3/8

0.375

3/8

12x1.50

13/32

0.406

13/32

12x1.75

13/32

0.406

13/32

Summary of Contents for Sportsman 90 2011

Page 1: ...ENTIFICATION NUMBER LOCATION 1 2 GENERAL SPECIFICATIONS 1 3 MODEL 2011 PREDATOR 50 1 3 MODEL 2011 OUTLAW 90 1 3 MODEL 2011 SPORTSMAN 90 1 3 MODEL 2011 PREDATOR 50 1 4 MODEL 2011 OUTLAW SPORTSMAN 90 1 5 MISCELLANEOUS INFORMATION 1 6 PUBLICATION NUMBERS 1 6 PAINT CODES 1 6 REPLACEMENT KEYS 1 6 SPECIAL TOOLS WHERE USED 1 7 STANDARD TORQUE SPECIFICATIONS 1 8 CONVERSION TABLE 1 9 SAE TAP DRILL SIZES 1 ...

Page 2: ... can be found stamped on the top LH side of the crankcase as shown below Vehicle Identification Number Location The vehicle identification number VIN and engine serial number are important for identification purposes See the illustrations below as a location reference Machine Model Number Identification Year Designation Basic Chassis Designation Engine Designation Emissions Model Option A 11 K A 0...

Page 3: ...41 kg Dry Weight 185 lbs 84 kg Oil Capacity 30 oz 900 ml Fuel Capacity 1 2 gal 4 5L Category Dimension Length 61 25 in 156 cm Width 36 75 in 93 cm Height 38 5 in 98 cm Wheel Base 41 5 in 105 cm Ground Clearance 4 in 10 cm at Swing Arm Rider Capacity Max Weight 1 rider 170 lbs 77 kg Dry Weight 283 lbs 128 kg Oil Capacity 30 oz 900 ml Fuel Capacity 1 7 gal 6 4 L Category Dimension Length 61 75 in 15...

Page 4: ...rve Capacity 0 22 gal 0 85 L Electrical Alternator Output 56 Watts 1700 RPM Voltage Regulator Single Phase Full Wave Daytime Running Lights 15 Watts Brake Light 21 watts Tail Light 5 watts Ignition System CDI Ignition Ignition Timing 17 5 BTDC 1700 RPM Spark plug Gap NGK CR6HSA 024 028 in 6 7 mm Battery Model Amp Hr Low Maintenance 12V 5 AH Fuses 1 7 Amp Starting Electric Kick Start Backup Indicat...

Page 5: ...ve Capacity 0 23 gal 0 86 L Outlaw 90 0 22 gal 0 85 L Sportsman 90 Electrical Alternator Output 56 Watts 1700 RPM Voltage Regulator Single Phase Full Wave Daytime Running Lights 15 Watts Brake Light 21 watts Tail Light 5 watts Ignition System CDI Ignition Ignition Timing 17 5 BTDC 1700 RPM Spark plug Gap NGK CR6HSA 024 028 in 6 7 mm Battery Model Amp Hr Low Maintenance 12V 5 AH Fuses 1 7 Amp Start...

Page 6: ...Replacement Keys Replacement keys can be made from the original key Polaris offers replacement key blanks 0453013 that can be cut to match the original Should both keys become lost ignition switch replacement is required Year Model Model No Owner s Manual PN Parts Manual PN 2011 Predator 50 A11KA05AB AD 9921811 9921812 2011 Outlaw 90 A11KA09AB AD 9921796 9921815 2011 Sportsman 90 A11FA09AA AB 9921...

Page 7: ... or by calling SPX 1 800 328 6657 PART NUMBER TOOL DESCRIPTION CHAPTER TOOL USED IN 2870872 Shock Spanner Wrench 2 5 PV 39951 A Tachometer 2 8 PV 35667 A Cylinder Leakdown Tester 2 3 2870390 Piston Support Block 3 PA 45153 Flywheel Puller 3 PA 46502 Valve Spring Compressor 3 PA 48701 Adaptor Valve Spring Compressor 3 PV 26900 8 26 Blade Thickness Gauge Feeler Gauge 3 PA 47361 Carburetor Adjustment...

Page 8: ...les Inc Standard Torque Specifications The following torque specifications are to be used as a general guideline There are exceptions in the steering suspension and engine areas Always consult the exploded views in each manual section for torque values of fasteners before using standard torque ...

Page 9: ...z lb x 454 kg kg x 2 2046 lb Cubic inches cu in x 16 387 Cubic centimeters cc Cubic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 Liters l Liters l x 1 76 Imperial pints Imp pt Imperial quarts Imp qt x 1 137 Liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt US quarts US qt x 0 833 Imperial quarts Imp qt US quarts US qt x 0 946 ...

Page 10: ... 10 24 24 1 1 4 12 1 11 64 10 32 21 1 1 2 6 1 11 32 12 24 17 1 1 2 12 1 27 64 12 28 4 6mm 1 3 4 5 1 9 16 1 4 20 7 1 3 4 12 1 43 64 1 4 28 3 2 4 1 2 1 25 32 5 16 18 F 2 12 1 59 64 5 16 24 I 2 1 4 4 1 2 2 1 32 3 8 16 O 2 1 2 4 2 1 4 3 8 24 Q 2 3 4 4 2 1 2 7 16 14 U 3 4 2 3 4 7 16 20 25 64 Tap Size Drill Size Decimal Equivalent Nearest Fraction 3x 50 39 0 0995 3 32 3x 60 3 32 0 0937 3 32 4x 70 30 0 1...

Page 11: ...oot feet Foot Pound Ft lb A force of one pound at the end of a lever one foot in length applied in a rotational direction g Gram Unit of weight in the metric system gal Gallon ID Inside diameter in Inch inches Inch Pound In lb 12 in lbs 1 ft lb kg cm2 Kilograms per square centimeter kg m Kilogram meters Kilogram meter A force of one kilogram at the end of a lever one meter in length applied in a r...

Page 12: ...NOTES GENERAL INFORMATION 1 12 ...

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