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T h e Wa y O u t .
PN 9918068




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  • Page 2: Scrambler

    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: Scrambler

    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.

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  • Page 9: Sportsman

    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

    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 P-067 Scrambler 90 Springs Yellow P-216...

  • 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: Youth Models

    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.

  • Page 20: Throttle Cable / Etc Adjustments

    GENERAL INFORMATION CHOKE (ENRICHER) 3. Start engine and set idle to specified RPM. NOTE: Be sure the engine is at operating ADJUSTMENT temperature. See Idle Speed Adjustment. 2003 Youth ATVs are fitted with a new manual choke 4. Loosen lock nut on in-line cable adjuster (Ill. 1). system.

  • Page 21: Oil Pump Adjustment / Bleeding

    OIL PUMP BLEEDING 2. Check and adjust throttle lever free play (ETC switch). 1. Fill the oil reservoir with Polaris injector oil. 3. Apply parking brake. 2. Loosen the pump bleed screw one full turn. Allow 4. Remove fan shroud.

  • Page 22: Oil Pump Troubleshooting

    GENERAL INFORMATION OIL PUMP TROUBLESHOOTING If you spill gasoline on your skin or clothing, immediately wash it off with soap and water PROCEDURE and change clothing. To verify oil delivery to engine, proceed as follows: Premix fuel in tank at a 40:1 fuel/oil ratio. Never start the engine or let it run in an enclosed area.

  • Page 23: Oil Tank

    GENERAL INFORMATION To service the fuel filter: 1. Shut off fuel supply at fuel valve. 2. Remove line clamps at both ends of the filter. 3. Remove fuel lines from filter. Drain Screw 4. Install new filter and clamps onto fuel lines. 5.

  • Page 24: Air Filter Service

    GENERAL INFORMATION 8. Start engine and re-check for leaks. 2. Remove the airbox cover to expose the filter element. Sportsman 90 Fuel Valve COMPRESSION TEST 3. Carefully wash the element in soapy water and dry it. Replace filter if necessary. 1.

  • Page 25: Wheel Installation

    Front Rear the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point 2 (Scrambler 50) 2 (Scrambler 50) toward forward rotation. 3 (Scrambler 90) 3 (Scrambler 90)

  • Page 26: Wheel Alignment

    NOTE: The steering post arm “frog” can be components are replaced, check front end alignment. used as an indicator of whether the handle- Use only genuine Polaris parts. bars are straight. The frog should always point straight back from the steering post.

  • Page 27

    GENERAL INFORMATION WHEEL ALIGNMENT TOE ALIGNMENT METHOD 2: CHALK ADJUSTMENT 1. Place machine on a smooth level surface. 1. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will 2. Set handlebars in a straight ahead position and tell you which tie rod needs adjusting.

  • Page 29: Engine / Transmission / Cvt

    ENGINE CHAPTER 2 ENGINE/TRANSMISSION/CVT Torque Specifications ......Special Tools ........CVT Exploded View .

  • Page 30: Torque Specifications

    Crankcase 0450700 Flywheel 25 ft.lbs (34 Nm) Separating Tool Oil Drain Bolt 14 ft.lbs (19 Nm) (Transmission) NOTE: Special tools can be ordered by Polaris Dealers only through SPX Corporation at (800) Oil Pump Bolts 43 in.lbs (5 Nm) 328--6657.

  • Page 31: Engine Removal

    ENGINE ENGINE REMOVAL 2. Remove the air box and carburetor from the chassis. REMOVE BODY PANELS Air Box and Carburetor SPORTSMAN 3. Loosen and remove the drive chain from the drive sprocket. Loosen the exhaust mounting bolts from under the engine. Remove any other muffler SCRAMBLER / PREDATOR mountings from the engine.

  • Page 32: Engine Disassembly

    Engine Break In Period Engine Break-In Period is defined as the first 10 hours of engine operation, or 2 full tanks of fuel. 1. Use only Polaris Premium 2 cycle engine oil. Never substitute or mix oil brands. Serious engine damage can result.

  • Page 33

    ENGINE 3. Remove the drive belt. 6. Remove the primary fixed sheave and washer claw. 4. Remove the idle gear plate, two washers, and idle 7. Remove the bushing, the primary sliding sheave, gear from the pin shaft. and the cam plate assembly. Primary Sheave NOTE: There is one washer on the inside of the idle NOTE: When removing the primary sliding sheave...

  • Page 34

    ENGINE 9. Remove the washer and needle bearing. 12. Remove the spring washer and nut from the shaft. Washer Needle Bearing 10. Remove the driven clutch assembly by removing 13. Remove the flywheel using flywheel puller. the O--ring and nut from the shaft. . Replace the O--ring as needed.

  • Page 35

    ENGINE 15. Remove the stator gasket, clean the area 18. Remove the dowel pin from the crankshaft. thoroughly. Loosen and remove the oil pump. The oil pump slides out in the forward direction. OIl Pump 19. Remove the external circlip from the crankshaft. 16.

  • Page 36

    ENGINE 21. Remove the cylinder head nuts and remove the 24. Remove the piston pin clip and the piston pin. cylinder head. Clean the cylinder head using parts washer solvent. 25. Remove the needle bearing from the piston pin NOTE: During reassembly use new gaskets. bore.

  • Page 37

    ENGINE 27. Remove the intake manifold and reed valve 30. Use the crankshaft removal tool to remove the assembly. Replace all gaskets. crankshaft. Crankcase Separation Crankshaft Removal Tool: 28. Remove all of the bolts from the crankcase to split (PN 0450697) the case.

  • Page 38: Transmission Service

    ENGINE TRANSMISSION SERVICE 3. Remove the washer and the driven clutch gear. NOTE: Engine removal is required to service transmission components. Refer to beginning of this chapter for removal instructions. 1. Drain the oil from the gear case. 4. Remove the drive axle assembly. Inspect for signs of wear.

  • Page 39: Engine Component Inspection

    ENGINE Driveshaft (Transmission) Assembly excessive, resurfacing head or replacement is needed. 6. Install the drive axle assembly, washers, main axle and primary axle. Refer to 2.10 for order of assembly. Main Axle Drive Axle Assy. Primary Drive Assy. Cylinder Head Warp Service Limit: .002I (0.05 mm) 7.

  • Page 40

    Piston Ring Installed Gap 2. Position piston ring 1/2² (1.3 cm) from the top of the Polaris recommends using only a rigid hone or arbor cylinder using the piston to push it squarely into honing machine which has the capability of place.

  • Page 41: Electrical

    (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant to prevent the formation of rust. Piston Pin Inspection 1.

  • Page 42: Scrambler

    ENGINE CRANKSHAFT RUNOUT Lubricate the bearings and clamp the crankshaft securely in the holding fixture. Refer to the illustrations. Connecting Rod Small End Service Limit .553I (14.04 mm) Crankshaft Alignment Fixture Reed Valve Inspection (PN 2870710) 1. Measure the air gap between fiber reed and reed block as shown.

  • Page 43: Scrambler

    ENGINE CVT SYSTEM DISASSEMBLY Primary Sheave 1. Remove the drive belt. NOTE: When removing the primary sliding sheave and the cam plate assembly, use two hands to hold the cam plate and the primary sliding sheave together. This prevents the roller weights from falling out of the 2.

  • Page 44

    ENGINE CVT Driven Clutch Cover and Lining the belt is .626² (15.9 mm). If the width of the belt is less than the service limit, or if the belt is worn, 1. Inspect the condition of the clutch cover. Measure glazed or hourglassed, replace.

  • Page 45

    ENGINE 3. Install the bushing, the primary sliding sheave, and 6. Install the inside washer, the idle gear, and the the cam plate assembly. outside washer onto the pin shaft. Primary Sheave 7. Install the idle gear plate. Torque the bolts to specification.

  • Page 46: Engine Reassembly

    ENGINE 9. Install the drive belt. Oil Pump Installation 3. Install the dowel pin into the crankshaft. ENGINE REASSEMBLY 4. Install the oil seal bracket. NOTE: Be sure to reinstall all of the bearings, seals, and retaining rings before the crankcase is reassembled. Crankcase 1.

  • Page 47

    8. Refill the oil pump gear chamber with the same amount of grease that was removed from the chamber during disassembly. Stator Trigger / Flywheel Gap: .020- -.040” (.5- -1.0 mm) Polaris All Season Grease (14 oz) (PN 2871423) 2.19...

  • Page 48

    ENGINE 11. Install the flywheel and flywheel nut. Torque to 13. Carefully install the new piston rings, so no specification. damage is done to the piston or ring lands. Piston Installation Flywheel Nut Torque: 14. Install the needle bearing into the piston pin bore. 25 ft.lbs.

  • Page 49

    ENGINE 16. Make sure cylinder surfaces are clean and free 19. Install the fan. Torque the fan bolts to specification. from debris. Install the cylinder gasket, cylinder, cylinder head gasket, and cylinder head. Torque the cylinder head nuts to specification. Fan Bolt Torque: 84 in.lbs.

  • Page 50

    ENGINE 22. Install the kick crank assembly onto the kick shaft. 25. Install the fan cover. 23. Carefully install the engine into the chassis. Secure 26. Connect the exhaust pipe to the engine and frame the engine with the engine mounting bolts. mounting areas.

  • Page 51

    ENGINE KICK START ASSEMBLY 3. Grease and install the bushing in the kick shaft boss. NOTE: This procedure is used to re--wind the kick start spring if the spring or any related components are disassembled for service. It is not necessary to remove the kick start lever or kick drive components to remove the engine cover.

  • Page 52: Starter Drive One Way Clutch

    ENGINE 6. Release the cover from the vise. Turn the cover 2. Remove the idle gear plate, two washers, and idle over while holding the spring and shaft assembly gear from the pin shaft. in place, and install the washer. NOTE: There is one washer on the inside of the idle gear and one washer on the outside of the idle gear.

  • Page 53

    ENGINE that easily come out of place. Upon assembly, do not Restricted filter (main lubricate the one way rollers with heavy grease, as pre-cleaner) or breather system this will cause the one- -way drive to malfunction. Improperly assembled air intake system 5.

  • Page 54

    ENGINE Spark plug fouled Excessive Smoke and Carbon Buildup Cylinder, piston, ring, or reed wear or Excessive piston-to-cylinder damage (check compression) clearance CVT not operating properly Worn rings, piston, or cylinder Restricted exhaust muffler Restricted breather Carburetor slide sticking or damaged Air filter dirty or contaminated Dirty carburetor Oil pump misadjusted or faulty...

  • Page 55

    FUEL SYSTEM/CARBURETION CHAPTER 3 CARBURETION Carburetor Exploded View ......Carburetor Special Tools ......Carburetor Specifications .

  • Page 56

    FUEL SYSTEM/CARBURETION CARBURETOR 90cc A03FA09CA / 50cc A03EA05CA Ref. Part No. Qty. Description Ref. Part No. Qty. Description 1. 0450120 1 Nut, Cable Adjust 15. 0450108 1 Bolt, Pan, Phillips 2. 0450847 1 Gasket 16. 0450895 1 Valve Set, Needle 3.

  • Page 57: Jetting Guidelines

    In higher elevations and higher temperatures, the air is less dense with reduced oxygen. Polaris Youth Carburetors are calibrated for an altitude of 0-6000 ft. (0-1800 meters) and ambient temperatures between +40 and +80° F (+5° to +26° C).

  • Page 58: Carburetor Specifications

    The oil check valve has a higher resistance spec to eliminate leaking oil into the carb. HIGH ALTITUDE OPERATION Scrambler 50 2003 Youth ATVs have been tested to 12,000 ft above Cutaway sea level to assure satisfactory performance. No...

  • Page 59: Float System

    FUEL SYSTEM/CARBURETION The engine of a vehicle is operated under a wide range of conditions, from idling with the throttle valve remaining almost closed, to full load or maximum output with the throttle valve fully opened. In order to meet the requirements for the proper mixture ratio under these varying conditions, a low speed fuel system, or pilot system, and a main fuel system are Fuel Supply...

  • Page 60: Jet Needle / Needle Jet / Throttle Opening

    FUEL SYSTEM/CARBURETION AIR SCREW throttle valve opening (between 1/4 and 3/4 opening). The air screw controls the fuel mixture from idle to low Having the proper needle jet and jet needle has a speeds. The tapered tip of the air screw projects into major impact on engine performance at partial load.

  • Page 61

    FUEL SYSTEM/CARBURETION inside the needle jet. THROTTLE SLIDE The throttle slide controls the rate of engine air intake by moving up and down inside the main bore. At small Needle Jet throttle openings, air flow control is performed chiefly by the cutaway. By controlling air flow the negative pressure over the needle jet is regulated, in turn varying the fuel flow.

  • Page 62: Pilot System

    FUEL SYSTEM/CARBURETION PILOT SYSTEM SLIDE CUTAWAY (Idle-3/8 THROTTLE) (1/8-3/8 Throttle) The pilot system’s main function is to meter fuel at idle Throttle valve cutaway effect is most noticeable at 1/4 and low speed driving. Though its main function is to throttle opening.

  • Page 63: Fuel Delivery

    FUEL SYSTEM/CARBURETION During low speed driving, there is very little clearance between the jet needle and the needle jet; therefore, General Carburetor Representation very little fuel from the main jet can pass between the jet needle and the needle jet. As the throttle valve Clip Position opening is increased, the tapered jet needle is raised (Shown in #3)

  • Page 64: Needle And Seat Leakage Test

    FUEL SYSTEM/CARBURETION 3. The float should be parallel ±1 mm to the gasket The jet needle and needle jet have an effective operating range from approximately 1/8 to 7/8 throttle surface on all youth model ATV carburetors. opening. The amount of fuel delivered during this When setting the float, be sure inlet needle valve range relies upon the jet needle clip position, as well spring is not compressed.

  • Page 65: Carburetor Float Bowl Draining

    FUEL SYSTEM/CARBURETION CARBURETOR FLOAT BOWL DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before extended periods of storage. NOTE: A drain plug is located on the side of the float bowl.

  • Page 66: Cold Weather Starting Procedure

    PROCEDURE Youth ATV Cold Weather Starting Procedure (Less Than 40_F (4_C)) NOTE: Polaris Youth ATVs are factory jetted for 40- -80_F (4- -27_C). 1. If the ATV has not been driven recently or has “summer gas”, replace the fuel in the tank with “winter gas” and drain the fuel from the float bowl until it has fresh fuel (photo 1).

  • Page 67: Troubleshooting

    FUEL SYSTEM/CARBURETION TROUBLESHOOTING FUEL STARVATION/LEAN MIXTURE POOR IDLE Symptoms: Idle too high. Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, Idle adjusted improperly/idle detonation, low power, spark plug erosion, engine mixture screw damaged runs hot, surging, high idle, idle speed erratic. Sticky throttle valve No fuel in tank Throttle cable sticking, improperly...

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  • Page 69

    BODY/STEERING/SUSPENSION CHAPTER 4 BODY/STEERING/SUSPENSION Frame Photos ....... . Torque Specifications / Special Tools .

  • Page 70

    BODY/STEERING/SUSPENSION FRAME Side View Front View Rear View ENGINE MOUNTING Rubber Bushings Engine Bracket Rubber Bushing Mount Tube...

  • Page 71: Torque Specifications / Special Tools

    BODY/STEERING/SUSPENSION TORQUE SPECIFICATIONS ENGINE MOUNTING A-Arm Attaching Bolt 26-30 ft. lbs. (36-40 Nm) 1. Install rubber dampers under footrest and install footrest on frame body. Handlebar Adjuster Block 84 in. lbs. (10 Nm) Rear Shock Bolts 25 ft. lbs. (35 Nm) Rear Wheel Hub Nut 78-81 ft.

  • Page 72: Shocks And Springs

    BODY/STEERING/SUSPENSION SHOCKS AND SPRINGS SUSPENSION A-ARMS Upper Spindle Bushing Right A-arm Grease Fitting Rear Shock and Spring Lower Spindle Bushing Bushings Right Spindle Left A-arm Front Shocks and Springs 1. The front shocks and springs are mounted on the Left Spindle frame and A-arm.

  • Page 73: Steering

    BODY/STEERING/SUSPENSION 2. Grease spindles and mount the spindles on the 1. Grease the steering post sleeve and insert in A-arms. The spindle marked “R” is for right side, place. Mount the steering post clamps on post. and “L” for left side. Torque the spindle nut to Install the steering post and tighten the steering specification.

  • Page 74: Front Brake

    BODY/STEERING/SUSPENSION 3. Mount the tie rod to the steering post and to the FRONT BRAKE spindle. Mount the tie rod so that the end with the flats is toward the spindle. Brake Cable Tie Rod Brake Shoes Return Steering Nut Spring Retainer Spring...

  • Page 75: Rear Brake And Axle

    BODY/STEERING/SUSPENSION 3. Mount the front brake assembly on the spindle. 1. Apply grease to the swing arm spacer tube. The swing arm assembly must be mounted first. NOTE: The swing arm assembly includes chain 4. Mount the brake drum on the backing plate protector.

  • Page 76

    BODY/STEERING/SUSPENSION 4. Install the rear axle bearing carrier and rear brake assembly on swing arm. Spacer Tube 8. Install the wheel hub and tighten axle nut to 5. Install rear axle. Tighten the bolts until snug. The specification. rear axle bearing carrier needs to be adjusted for chain tension.

  • Page 77: Fuel And Oil Tank

    BODY/STEERING/SUSPENSION 11. Set the chain tension to specification by loosening FUEL AND OIL TANK the lock nuts on the chain adjuster. Turn the 1. Install fuel tank in the frame and tighten bolts to adjuster until the chain tension is set. Tighten the specification.

  • Page 78: Scrambler Front And Rear Cab

    BODY/STEERING/SUSPENSION SCRAMBLER FRONT AND 3. Install the front and rear cab to the frame and tighten the mounting bolts to specification. REAR CAB INSTALLATION Front Cab Assy. Rear Cab Assy. 1. Install the bumper to the frame and tighten mounting bolts to specification. Cab Mounting Bolt Torque: 103 in.lbs.

  • Page 79: Sportsman Handlebar Assembly

    BODY/STEERING/SUSPENSION SPORTSMAN HANDLEBAR Front Bumper Mounting ASSEMBLY Bolt Torque: 103 in.lbs. (12 Nm) UPPER POD ASSEMBLY Handlebar 2. There are three (3) mounting positions for the Grip front and rear cab to the frame. The front cab is BOLTS mounted on positions 1 and 2. The rear cab is mounted on position 3.

  • Page 80

    BODY/STEERING/SUSPENSION 3. Install the handlebar. Secure the handlebar with 6. Check freeplay of the right side and left side front the clamps and bolts, but do not tighten at this brake cables as shown. Adjust to specification. point. 4. Position and tighten the left and right side controls and brake lever clamps.

  • Page 81: Scrambler Handlebar Assembly

    BODY/STEERING/SUSPENSION 8. Open the throttle ETC switch box and lightly grease SCRAMBLER HANDLEBAR the throttle cable (A). Install the throttle cable. ASSEMBLY Electronic Throttle Control (ETC) Switch (Cast Aluminum Throttle Housing) ROUND NUTS Right Hand Control HANDLEBAR COVER Handlebar BOLTS Grip SPACERS ETC Micro...

  • Page 82

    BODY/STEERING/SUSPENSION 3. Install the handlebar. Secure the handlebar with 6. Check freeplay of the right side and left side front the clamps, spacers,bolts, and nuts, but do not brake cables as shown. Adjust to specifications. tighten at this point. 4. Position and tighten the left and right side controls and brake lever clamps.

  • Page 83

    BODY/STEERING/SUSPENSION 8. Open the throttle ETC switch box and lightly 1. Connect the muffler to the cylinder and install. grease the throttle cable (A). Install the throttle Inspect sealing gaskets upon installation. cable. Replace if necessary. Electronic Throttle Control (ETC) Switch (Cast Aluminum Throttle Housing) 2.

  • Page 84


  • Page 85

    ....5.17 Wiring Diagram - Scrambler 50 ....

  • Page 86: Special Tools

    Electronic Speed Control System Become familiar with the operation of 2003 Polaris Youth ATVs are equipped with an your meter. Be sure leads are in the electronic speed control system, which controls the proper jack for the test being engine RPM and speed of the ATV.

  • Page 87: Brakelight Bulb Replacement

    ELECTRICAL BRAKE LIGHT BULB REPLACEMENT If the brake light does not work the bulb may need to be replaced. Lens Cover Bulb 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens SPEED CONTROL SYSTEMS cover.

  • Page 88: Battery Activation

    NOTE: Do not activate the battery unless it will be put into regular service within 30 days. Polaris Youth ATV BATTERY TERMINALS/ batteries are a maintenance--free design. Do not attempt to add water or electrolyte.

  • Page 89: Battery Inspection/ Removal

    REMOVAL Whenever a service complaint is related to either the starting or charging systems, the battery should be NOTE: Polaris Youth ATVs use a maintenance free checked first. battery. Do not remove the battery cap strip to check the acid level. Perform the proper battery tests and Following are two tests which can easily be made on replace the battery as needed.

  • Page 90: Off Season Storage

    ELECTRICAL OFF SEASON STORAGE Routine Maintenance Youth ATV Batteries To prevent battery damage during extended periods Check voltage periodically using a voltmeter of non-use, the following basic battery maintenance items must be performed: Check voltage every 3--6 months Remove battery from depending on temperature.

  • Page 91

    ELECTRICAL charging times carefully, or use a charger with limited charging time/current capabilities. Polaris recommends using Christie Multi--Battery Charger PV--67030, available from our tool provider SPX for charging batteries. Always stop charging if the battery becomes warm to the touch. Let it cool sufficiently before resuming charging.

  • Page 92: Charging System Testing

    ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected, proceed with the following system check. Using a multitester set on D.C. volts, mea- sure the battery open circuit voltage (See Remove the battery and properly ser- Page 5.5). It should be 12.5 volts or more. vice.

  • Page 93: Current Draw / Key Off Test

    ELECTRICAL CURRENT DRAW - KEY OFF With engine off and the key and kill switch in the ON position, the ammeter should read negative amps CAUTION: Do not connect or disconnect the (battery discharge). Reverse meter battery cable or ammeter with the engine running. leads if a positive reading is Damage will occur to tail light bulb.

  • Page 94: Starter System Troubleshooting / Voltage Drop Test

    ELECTRICAL Connect the meter leads to the Faulty starter button Yellow/Red and Black wires leading Faulty ignition switch (Do other from the alternator. systems function?) Start the engine using the kick Faulty starter solenoid or starter staRter and let it idle. Reading motor.

  • Page 95

    ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system. A digital multitester must be used for this test. With the tester on the VDC position, place the tes- ter’s black lead on the battery negative and the red Remove battery and properly service.

  • Page 96: Starter Motor Disassembly

    ELECTRICAL STARTER MOTOR 3. Remove housing while holding the armature and brush holder section together. DISASSEMBLY Washer Bolt Oil Ring Brush Set Cord Oil Ring NOTE: Use only electrical contact cleaner to clean starter motor parts. Other solvents may leave a BRUSH INSPECTION/ residue or damage internal parts and insulation.

  • Page 97: Armature Testing

    ELECTRICAL 3. Remove brush plate and brushes. Measure 4. Measure resistance between each length of brushes and replace if worn past the commutator segment and the armature shaft. service limit. The reading should be infinite (no continuity). Brush Length 5/16” 5.

  • Page 98: Electronic Throttle Control (etc)

    ELECTRICAL Electronic Throttle Control Throttle is ETC Switch is Open Closed. Connec- tion from Grey to Black. Throttle is ETC Switch Open. Closed NO connection from Grey to Black. In the Event of With cable slack Cable Slack the ETC is open, there is NO con- nection from grey 6.

  • Page 99: Cranking Tests

    ELECTRICAL CRANKING TESTS Unloaded Cranking Voltage Wire Color Wire Description A/C Output Yellow/Red to Black 3 Prong Plug 4.5--5.9 Volts AC White to Black 3 Prong Plug 5.3--7.0 Volts AC White/Red to Black Bullet Connector 0.3--0.4 Volts AC Black/Red to Black Bullet Connector 90--120 Volts AC Peak Reading Cranking Voltage...

  • Page 100: Ignition System Troubleshooting

    ELECTRICAL COIL TESTING Conntector Meter Reading Yellow Red to 4.5--5 Volts AC Coil Primary Winding Black (Engine Cranking) Yellow Red to 7 to 9 Volts AC Black (Engine Running) Black Spade Wire Description Resistance Yellow/Red Spade Connection 0.5 -- 1.0 Ohms to Ground Plug Cap 4--5 K Ohms...

  • Page 101: Quick Reference Diagram

    ELECTRICAL QUICK REFERENCE DIAGRAM Scrambler 50/90, Predator 90 & Sportsman 90 Quick Reference Wire Diagram Battery ETC Switch is OPEN the engine is limited to 1500 RPM. Main Switch NOTE: CDI BLK/WHT must have ground to run. BRN (Splice) Brake...

  • Page 102


  • Page 103: Scrambler 90/sportsman 90/predator 90 Wiring Diagram


  • Page 104

    Carburetor Needle and Seat Testing, 3.10 Carburetor Operation, 3.4 A--arm Mounting Bolt Torque, 4.4 Carburetor Specifications, 3.4 Air Cleaner, 1.18 Carburetor System Function, 3.3 Air Screw, 3.6 Carburetor Venting Systems, 3.10 Air Screw Adjustment, 1.13 Chain Adjuster Lock Nut Torque, 1.11 Air Screw Adjustment Specifications, 1.13 Chain Adjustment, 1.10 Air/Fuel Mixture Ratio, 3.6...

  • Page 105

    Cylinder Inspection, 2.11 Fuel Line Maintenance, 1.16 Fuel System Warnings, 1.16 Cylinder Warp, 2.11 Fuel Tank Mounting Bolt Torque, 4.9 Decimal Equivalents, 1.7 Glossary of Terms, 1.8 Drive Belt Width Service Limit, 2.16 Grease Fitting Lubrication, 1.11 Drive Clutch Nut Torque, 2.17 Driven Clutch Nut Torque, 2.17 Driveshaft (Transmission) Assembly, 2.11 Handlebar Asm., Scrambler, 4.13...

  • Page 106

    Model Identification, 1.2 Rear Brake Inspection, 1.10 Rear Shock and Spring Inspection, 1.11 Motor Mount Bolt Torque, 4.3 Rear Shock Mounting Bolt Torque, 4.7 Muffler, 4.15 Reed Valve Air Gap Service Limit, 2.14 Muffler Mounting Bolt Torque, 4.15 Reed Valve Inspection, 2.14 Needle Jet, 3.6 Serial Number Locations, 1.2 New for 2002 Models, 1.9, 5.2...

  • Page 107

    Wheel Nut Torque, 1.12 Troubleshooting, Engine, 2.25 Wheel Removal, 1.18 Troubleshooting, Fuel System/Carb, 3.13 Wiring Diagram, Quick Reference, 5.17 Troubleshooting, Ignition System, 5.16 Wiring Diagram, Scrambler 50, 5.18 Troubleshooting, Spark Plug, 2.25 Wiring Diagram, Scrambler 90/Sportsman Troubleshooting, Starter System, 5.10 90/Predator 90, 5.19...

  • Page 109

    PN 9918068 Printed in USA...

This manual also for:

Scrambler 90, Sportsman 90, Predator 90

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