Polaris 2003 Scrambler 50 Service Manual
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Polaris 2003 Scrambler 50 Service Manual

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See also: Owner's Manual
T h e Wa y O u t .
SCRAMBLER 50
SCRAMBLER 90
SPORTSMAN 90
PREDATOR 90
SERVICE MANUAL
PN 9918068

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Summary of Contents for Polaris 2003 Scrambler 50

  • Page 1 T h e Wa y O u t . SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 SERVICE MANUAL PN 9918068...
  • Page 2 2003 Sportsman Youth ATV Service Manual (PN 9918068) ECopyright 2002 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvement in the design and quality of production components, some minor descrepancies may result between the actual vehicle and the information presented in this publication.
  • Page 3 NOTE: A NOTE provides key information to clarify instructions. Trademarks Polaris acknowledges the following products mentioned in this manual: FLEXLOC, Registered Trademark of SPS Technologies Loctite, Registered Trademark of the Loctite Corporation STA-BIL, Registered Trademark of Gold Eagle FOX, Registered Trademark of Fox Shox Nyogel, Trademark of Wm.
  • Page 4 Table of Contents PN 9918068 Chapter 1 General Information Maintenance Chapter 2 Engine / Transmission / CVT Chapter 3 Carburetion Chapter 4 Body / Steering suspension Chapter 5 Electrical...

  • Page 5: Table Of Contents

    GENERAL INFORMATION CHAPTER 1 GENERAL INFORMATION/ MAINTENANCE Serial Number Location ..... . . 2003 Youth Models ......Specifications .

  • Page 6: Serial Number Location

    GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 3 E A 0 5 C A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation VIN IDENTIFICATION World Mfg.

  • Page 7: Youth Models

    GENERAL INFORMATION 2003 YOUTH MODEL ATVS SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 NOTE: Colors will vary upon model.
  • Page 8 GENERAL INFORMATION...

  • Page 9: Specifications

    GENERAL INFORMATION SPECIFICATIONS MODEL SCRAMBLER 50 SCRAMBLER 90 PREDATOR 90 SPORTSMAN 90 ENGINE TYPE 2-Stroke Horizontal 2-Stroke Horizontal 2-Stroke Horizontal 2-Stroke Horizontal (AR03--01) (AR07--01) (AR07--01) (AR07--01) NUMBER OF CYLINDERS DISPLACEMENT 49.3 cc 89.2 cc 89.2 cc 89.2 cc BORE AND STROKE 1.58x1.54²...

  • Page 10: Publication Numbers

    Predator 90 A03KA09 9918312 9918313 9918314 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER Scrambler 50 Springs Yellow P-216 Sportsman 90 Springs Medium Gloss Black 9440...

  • Page 11: Standard Torque Specifications

    GENERAL INFORMATION STANDARD TORQUE NOTE: Special tools can be ordered by Polaris Dealers only through SPX Corporation at (800) SPECIFICATIONS 328--6657. The following torque specifications are to be used as POLARIS LUBRICANT AND a general guideline. There are exceptions in the steering, suspension, and engine areas.
  • Page 12 GENERAL INFORMATION CONVERSION TABLE Unit of Measure Multiplied by Converts to ft. lbs. x 12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m x .7376 = ft.lbs. kg-m x 7.233 = ft.
  • Page 13 GENERAL INFORMATION SAE TAP DRILL SIZES DECIMAL EQUIVALENTS 1/64 ....0156 Thread Size/Drill Size Thread Size/Drill Size 1/32 ... .0312 .

  • Page 14: Glossary Of Terms

    Center Distance: Distance between center of crankshaft and center of driven clutch shaft. Chain Pitch: Distance between chain link pins (No. 35 = 3/8² or 1 cm). Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.
  • Page 15 1. Loosen the jam nut (A) Electronic Speed Control System 2. Turn the screw (B) inward to reduce speed or Your Polaris ATV is equipped with an electronic speed outward to increase speed. control system, which controls the engine RPM and 3.

  • Page 16: Vehicle Inspection/Adjustments

    GENERAL INFORMATION VEHICLE INSPECTION REAR BRAKE 3. The rear brake is operated using the left hand brake lever. To adjust the rear brake setting, turn the FRONT BRAKE rear brake adjuster nut until brake is set to 1. Each front brake has a cable connected to the right specification.
  • Page 17 1. Inspect the rear shock and spring to ensure proper function. If the shock is leaking oil, replace. LUBRICATION Inspect the swing arm and weldments for any sign of damage. 1. Lubricate grease fittings on spindles monthly with Polaris All Season Grease, or more frequently if used often. 1.13...

  • Page 18: Transmission Lubrication

    It should be checked monthly and changed annually. With the ATV on a level surface, check the oil level through the sight glass. If the level is low, add Polaris Wheel Nut Torque: Premium Synthetic Gearcase Lubricant. See page 1.6 for the part numbers of Polaris-recommended...

  • Page 19: Throttle Operation / Air Screw Adjustment

    GENERAL INFORMATION To change lubricant: Air Screw Adjustment: 1. Place a drain pan beneath the transmission 50 cc: 1/2 Turn Out from Lightly Seated lubricant drain plug area. 90 cc: 1 Turn Out from Lightly Seated 2. Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings.

This manual is also suitable for:

2003 predator 902003 sportsman 902003 scrambler 90

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