2003 Polaris ATV Scrambler 50 Predator 90 Scrambler 90 Sportsman 90 Service Maintenance Manual
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LANGUAGE:ENGLISH
PAGES:109
DOWNLOADABLE:YES
FILE TYPE:PDF
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2003 Polaris ATV Scrambler 50 Predator 90 Scrambler 90 Sportsman 90 Service Maintenance Manual
Foreword:
This manual is designed primarily for use by certified Polaris Master Service Dealer technicians in a properly equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from the operator’s perspective when seated in a normal riding position. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
- Technicians should read the text and be familiar with service procedures before starting the work. Certain procedures require the use of special tools. Use only the proper tools as specified.
- This manual includes procedures for maintenance operations, component identification and unit repair, along with service specifications for the 2003 Polaris Scrambler 50, Predator 90, Scrambler 90, and Sportsman 90. Comments or suggestions about this manual may be directed to: Service Publications Dept.@Polaris Sales Inc. 2100 Hwy 55 Medina Minnesota 55340.
TABLE OF CONTENTS:
2003 Polaris ATV Scrambler 50 Predator 90 Scrambler 90 Sportsman 90 Service Maintenance Manual
GENERAL INFORMATION/
MAINTENANCE
Serial Number Location12
2003 Youth Models13
Specifications 14
Publication Numbers 15
Paint Codes15
Inspection Schedule 15
Standard Torque Specifications 16
Lubricant and Maintenance Products 16
Special Tools16
Unit of Measure Conversion Table 17
Tap Drill Charts18
Decimal Equivalent Chart 18
Glossary of Terms 19
2003 Models ESLS110
Vehicle Inspection/Adjustments111–113
Transmission Lubrication 113–114
Throttle Operation / Air Screw Adjustment114
Idle Speed Adjustment 114
Throttle Cable / ETC Adjustments 115–116
Oil Pump Adjustment / Bleeding 116
Oil Pump Troubleshooting117
Fuel System117–118
Compression Testing 119
Air Filter Service 119
Wheels and Tires119–121
Steering / Alignment 121–122
ENGINE/TRANSMISSION/CVT
Torque Specifications 22
Special Tools 22
CVT Exploded View 22
Engine Removal23-24
Engine Disassembly24-29
Transmission Service 210-211
Engine Component Inspection 211-212
Cylinder Honing212-214
Crankshaft Runout Inspection214
Constant Variable Transmission (CVT) Service 216-218
Engine Reassembly 218-222
Kick Start and Spring Installation 223-224
Starter Drive One Way Clutch224-225
Engine Troubleshooting 225-226
CARBURETION
Carburetor Exploded View 32
Carburetor Special Tools33
Carburetor Specifications34
Optional Main Jets34
Carburetor Operation 34–310
Float System 35
Pilot Jet / Pilot Air Screw / Air/Fuel Mixture 35–36
Jet Needle / Needle Jet / Throttle Opening 36–37
Throttle Valve / Main Jet 37
Pilot System 38
Slide Cutaway / 1/8–3/8 Throttle38
Jet Needle/ Needle Jet 3/8–3/4 Throttle 39
Main Jet 3/4 to Full Throttle39
Fuel Delivery 39–310
Vent System / Float Height 310
Needle and Seat Leakage Test 310
Carburetor Float Bowl Draining 311
Cold Weather Starting Procedure 312
Troubleshooting313
Frame Photos 42
Torque Specifications / Special Tools 43
Engine Mounting Exploded View43
Engine Mounting43
Shocks and Springs 44
Suspension A–Arms 44
Steering45
Front Brake46–47
Rear Brake and Axle 47–49
Fuel and Oil Tank49
Scrambler Front and Rear Cab410
Sportsman Front and Rear Cab 410–411
Sportsman Handlebar Assembly 411–413
Scrambler Handlebar Assembly 413–415
Muffler Assembly415
Special Tools52
Electrical Service Notes52
2003 Models ESLS52–53
Brakelight Bulb Replacement 53
Battery Service / Terminals and Bolts 53–54
Battery Inspection / Removal55
Battery Installation 55
Open Circuit Voltage Test 55
Load Test 55
Off Season Storage56
Charging Procedure 56
Charging System Testing 57
Current Draw / Key Off Test 58
Charging System Break Even Test 59
Alternator Output Test59
Ignition System / Spark Plug510
Starter System Troubleshooting / Voltage Drop Test510
Starter System Diagnosis 511
Starter Motor Disassembly512
Brush Inspection / Replacement 512–513
Armature Testing513
Starter Assembly513–514
Electronic Throttle Control (ETC)514
Cranking Tests515
Coil and Enrichment Valve Tests 516
Ignition System Troubleshooting 516
Quick Reference Electrical Diagram517
Wiring Diagram – Scrambler 50518
Wiring Diagram – 90 CC Models 519
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