Polaris Scrambler 50 User manual

PN 9918068
Printed in USA
2003YOUTH ATV SERVICE MANUAL PN 9918068
SCRAMBLER 50
SCRAMBLER 90
SPORTSMAN 90
PREDATOR 90
SERVICE MANUAL
PN 9918068
The Way Out.
223057_cover 7/29/02 11:23 AM Page 1

2003 Scrambler 50, Predator 90, Scrambler 90 , Sportsman 90
SERVICE 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.
Someproceduresoutlinedinthismanualrequireasoundknowledgeof mechanicaltheory, tooluse, andshop
procedures inorder to perform the work safely andcorrectly. Technicians should readthe 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 manualincludes proceduresformaintenanceoperations, componentidentificationandunitrepair,along
with service specifications for the2003 Polaris Scrambler 50, Predator 90, Scrambler 90, and Sportsman90.
Commentsor suggestionsaboutthismanualmay bedirectedto: ServicePublicationsDept. @PolarisSales
Inc. 2100 Hwy 55 Medina Minnesota 55340.
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. Depictions and/or procedures in this publication are
intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions
and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
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UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
Throughout these instructions, important information is brought to your attention by the following symbols:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
DANGER
Failure tofollowDANGER instructions willresultin severeinjuryordeathtotheoperator,bystander orperson
inspecting or servicing the ATV.
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the operator, bystander or
person inspecting or servicing the ATV.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid personal injury, or ATV or property
damage.
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. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity Vac, Registered Trademark of Neward Enterprises, Inc.
Ammco, Registered Trademark of Ammco Tools, Inc.
Torx, Registered Trademark of Textron
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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

1
GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION/
MAINTENANCE
Serial Number Location 1.2.......................
2003 Youth Models 1.3...........................
Specifications 1.4................................
Publication Numbers 1.5..........................
Paint Codes 1.5.................................
Inspection Schedule 1.5..........................
Standard Torque Specifications 1.6................
Lubricant and Maintenance Products 1.6............
Special Tools 1.6.................................
Unit of Measure Conversion Table 1.7..............
Tap Drill Charts 1.8...............................
Decimal Equivalent Chart 1.8......................
Glossary of Terms 1.9............................
2003 Models E.S.L.S. 1.10.........................
Vehicle Inspection/Adjustments 1.11--1.13.................
Transmission Lubrication 1.13--1.14......................
Throttle Operation / Air Screw Adjustment 1.14.......
Idle Speed Adjustment 1.14........................
Throttle Cable / ETC Adjustments 1.15--1.16..............
Oil Pump Adjustment / Bleeding 1.16................
Oil Pump Troubleshooting 1.17.....................
Fuel System 1.17--1.18.................................
Compression Testing 1.19..........................
Air Filter Service 1.19..............................
Wheels and Tires 1.19--1.21.............................
Steering / Alignment 1.21--1.22..........................
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GENERAL INFORMATION
1.2
MODEL IDENTIFICATION
The machine model number must be used with any correspondence regarding warranty or service.
Machine Model Number Identification
Year Designation Basic Chassis
Designation Engine Designation
A03EA05CA Emissions &
Model Option
VIN IDENTIFICATION
1 2 3 4 5 6 7 8 9 10 1112 13 14 15 16 17
RF 3 E A 05C*3T000000
Vehicle Descriptor Vehicle Identifier
PowertrainEngine
Emissions Model
YearPlant No. Individual Serial No.
Body Style
Check Digit
World Mfg. ID
* This could be either
a number or a letter
SERIAL NUMBER LOCATIONS
Whenever corresponding about an engine, be sure to refer to the engine serial number. This information can be
found stamped on the transmission section located by the transmission oil fill plug(A). The machine model
number and serial number are important for vehicle identification. The machine serial number is stamped on the
front of the frame (B).
Front
B
A
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GENERAL INFORMATION
1.3
2003 YOUTH MODEL ATVS
SCRAMBLER 50
SCRAMBLER 90
SPORTSMAN 90
PREDATOR 90
NOTE: Colors will vary upon model.
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GENERAL INFORMATION
1.4
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GENERAL INFORMATION
1.5
SPECIFICATIONS
MODEL SCRAMBLER 50 SCRAMBLER 90 PREDATOR 90 SPORTSMAN 90
ENGINE TYPE 2-Stroke Horizontal
(AR03--01)
2-Stroke Horizontal
(AR0 --01)
2-Stroke Horizontal
(AR0 --01)
2-Stroke Horizontal
(AR0 --01)
NUMBER OF CYLINDERS 1111
DISPLACEMENT 49.3 cc 89.2 cc 89.2 cc 89.2 cc
BORE AND STROKE 1.58x1.54²(40x39.2
mm)
2.05x1.65²(52x42
mm)
2.05x1.65²(52x42
mm)
2.05x1.65²(52x42
mm)
COMPRESSION RATIO 6.8:1 . :1 . :1 . :1
SPARK PLUG BPR HS BPR HS BPR HS BPR HS
ALTERNATOR OUTPUT 0 Watts @ 4000 RPM 0 Watts @ 4000 RPM 0 Watts @ 4000 RPM 0 Watts @ 4000 RPM
IGNITION TIMING ** 14°@ 1500 RPM** 16°@ 1500 RPM** 16°@ 1500 RPM** 16°@ 1500 RPM**
MAX. TORQUE 4 ft.lbs (5.4 Nm) @
6000 RPM
6.5 ft.lbs (8.82 Nm) @
6000 RPM
6.5 ft.lbs (8.82 Nm) @
6000 RPM
6.5 ft.lbs (8.82 Nm) @
6000 RPM
CARBURETOR Sunworld H68K Mikuni VM16 Mikuni VM16 Mikuni VM16
STARTING Electric/Kick Start Electric/Kick Start Electric/Kick Start Electric/Kick Start
BATTERY GTX5L--BS, 4.85 amp GTX5L--BS, 4.85 amp GTX5L--BS, 4.85 amp GTX5L--BS, 4.85 amp
LUBRICATION Oil Injection Oil Injection Oil Injection Oil Injection
OIL CAPACITY 1.05 Quarts (1 Liter) 1.05 Quarts (1 Liter) 1.05 Quarts (1 Liter) 1.05 Quarts (1 Liter)
TRANSMISSION Automatic (C.V.T. Sys-
tem)
Automatic (C.V.T. Sys-
tem)
Automatic (C.V.T. Sys-
tem)
Automatic (C.V.T. Sys-
tem)
FRONT SUSPENSION A-arm with 4.25²(10.8
cm) Travel
A-arm with 4.25²(10.8
cm) Travel
A-arm with 4.25²(10.8
cm) Travel
A-arm with 4.25²(10.8
cm) Travel
REAR SUSPENSION Single Shock/Swing
Arm with 4.25²(10.8
cm) Travel
Single Shock/Swing
Arm with 4.25²(10.8
cm) Travel
Single Shock/Swing
Arm with 4.25²(10.8
cm) Travel
Single Shock/Swing
Arm with 4.25²(10.8
cm) Travel
FRONT BRAKE Drum Drum Drum Drum
REAR BRAKE Drum Drum Drum Drum
PARKING BRAKE Mechanical Lock Mechanical Lock Mechanical Lock Mechanical Lock
FRONT TIRES 16x8- 18x - 18x - 19x -8
REAR TIRES 16x8- 18x9.5-8 18x9.5-8 18x9.5-8
TIRE PRESSURE 2psi 3psi 3psi 3psi
OVERALL DIMENSIONS 54.6x34x34. ²
(138. x86.3x88.2 cm)
5 x35. 5x36²
(145x91x91.8 cm)
5 x35. 5x36²
(145x91x91.8 cm)
5 x35. 5x36²
(145x91x91.8 cm)
WHEELBASE 35.4²(90 cm) 38.5²(98 cm) 38.5²(98 cm) 38.5²(98 cm)
TURNING RADIUS 4.8²(190 cm) 98.4²(250 cm) 98.4²(250 cm) 98.4²(250 cm)
SEAT HEIGHT 22.5²(5 cm) 24.5²(62 cm) 24.5²(62 cm) 24.5²(62 cm)
GROUND CLEARANCE 3²(8 cm) 4²(10 cm) 4²(10 cm) 5²(12 cm)
DRY WEIGHT 211.6 lbs. (96 kg) 233. lbs. (106 kg) 233. lbs. (106 kg) 238.1 lbs. (108 kg)
MAX. LOAD CAPACITY 100 lbs. (45.4 kg) 160 lbs. ( 2 kg) 160 lbs. ( 2 kg) 190 lbs. (86 kg)
FUEL REQUIREMENTS 8 Octane Unleaded 8 Octane Unleaded 8 Octane Unleaded 8 Octane Unleaded
FUEL CAPACITY 1.32 Gallons (5 Liters) 1.32 Gallons (5 Liters) 1.32 Gallons (5 Liters) 1.32 Gallons (5 Liters)
FRONT RACK CAPACITY N/A N/A N/A 10 lbs. (4.54 kg)*
REAR RACK CAPACITY N/A N/A N/A 20 lbs. (9.08 kg)*
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GENERAL INFORMATION
1.6
NOTE * Check owner’s manual for loading requirements and restrictions.** Specification is reference only -- not
adjustable.
PUBLICATION NUMBERS
Model Model No. Owner’s Manual PN Parts
Manual PN
Parts
Micro Fiche
PN
Scrambler 50 A03EA05 991 8 3 991 8 5 991 8 6
Sportsman 90 A03FA09 991 8 3 991 885 991 886
Scrambler 90 A03EA09 991 8 3 991 880 991 881
Predator 90 A03KA09 9918312 9918313 9918314
When ordering service parts be sure to use the correct parts manual.
PAINT CODES
PAINTED PART COLOR
DESCRIPTION
DITZLER
NUMBER
POLARIS
NUMBER
Scrambler 50 Springs Yellow N/A P-216
Sportsman 90 Springs Medium Gloss Black 9440 P-06
Scrambler 90 Springs Yellow N/A P-216
Predator 90 Springs Indy Red N/A P-293
Frame -- All Medium Gloss Black 9440 P-06
Order direct from Midwest Industrial Coatings (952-242-2000).
INSPECTION SCHEDULE
Service Item Initial Service
(After two weeks)
Monthly Every 6 Months Yearly
Air Cleaner C
Fuel Filter I
Fuel/Oil Lines I
Battery I I
Brake Shoes I
Spark Plug I
Chain Lubrication I
Steering Lubrication I
Carburetor C
Throttle Control I
Tire Pressure I
Fasteners T
Gear Oil R R
R = Replace C = Clean T =Tighten I = Inspect
NOTE Inspection schedules are for reference only. If the vehicle is used often, more frequent
inspections will be required.
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GENERAL INFORMATION
1.7
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 theexplodedviewsineachmanualsectionfor
torque values of fasteners before using standard
torque.
FASTENER TORQUE
(ft.lbs. / in.lbs.) TORQUE (Nm)
5 mm bolts
and nuts 39-52 in.lbs. 4.5-6 Nm
6 mm bolts
and nuts 69-104 in.lbs. 8-12 Nm
8 mm bolts
and nuts 13-18 ft.lbs 18-25 Nm
10 mm bolts
and nuts 22-29 ft.lbs. 30-40 Nm
12 mm bolts
and nuts 36-43 ft.lbs. 50-60 Nm
4 mm screws 22-30 in.lbs. 2.5-3.4 Nm
5 mm screws 30-43 in.lbs. 3.5-5 Nm
6mm
Hex bolts 87-121 in.lbs. 10-14 Nm
8mm
Hex bolts 17-22 ft.lbs. 24-30 Nm
10 mm
Hex bolts 25-32 ft.lbs. 35-45 Nm
SPECIAL TOOLS
DESCRIPTION PART NUMBER
Crankshaft
Removal Tool 0450697
Flywheel Puller PA--45153
Oil Pump Drive
Gear Removal Tool 0450699
Crankcase
Separating Tool 0450700
Shock Spanner
Wrench 2870872
Shock Spring
Compressor Tool 2870623
Battery Charger PV--37453
NOTE: Special tools can be ordered by Polaris
Dealers only through SPX Corporation at (800)
328--6657.
POLARIS LUBRICANT AND
MAINTENANCE PRODUCTS
Part No. Description
Engine Lubricant
2870791 Fogging Oil
2871098 Premium 2 Cycle Engine Oil (Quart)
2871097 Premium 2 Cycle Engine Oil (Gallon)
2871240 Premium 2 Cycle Engine Oil (2.5 Gallon)
2871566 Premium 2 Cycle Engine Oil (16 Gallon)
2871385 Premium 2 Cycle Engine Oil (30 Gallon)
2871240 Premium 2 Cycle Engine Oil (55 Gallon)
2871721 Premium Gold 2 Cycle Synthetic
Lubricant (Quart)
2871722 Premium Gold 2 Cycle Synthetic
Lubricant (Gallon)
Gearcase / Transmission Lubricants
2871477 Premium Synthetic Gearcase Lubricant
(1 Gal.)
2871478 Premium Synthetic Gearcase Lubricant
(12 oz.. bottle)
2870465 Oil Pump for Gearcase Oil
Grease / Specialized Lubricants
2871322 Premium All Season Grease (3 oz..
cartridge)
2871423 Premium All Season Grease (14 oz..
cartridge)
2871460 Starter Drive Grease
2871312 Chain Lube (6.25 oz.)
2871312 Grease Gun Kit
2871329 NyogeltGrease
Additives / Sealants / Thread Locking Agents / Misc.
2871326 Premium Carbon Clean 12 oz..
2870652 Fuel Stabilizer 16 oz..
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GENERAL INFORMATION
1.8
CONVERSION TABLE
Unit of Measure Multiplied by Converts to
ft. lbs. x12 =in.lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 =Nm
in. lbs. x .0115 =kg-m
Nm x .7376 = ft.lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 =in.lbs.
kg-m x10 =Nm
in. x 25.4 =mm
mm x .03937 =in.
in. x2.54 =cm
mile (mi.) x1.6 =km
km x .6214 = mile (mi.)
Ounces (oz) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz)
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) x1.76 = Imperial pints (Imp pt)
Imperial quarts (Imp qt) x 1.137 = Liters (l)
Liters (l) x0.88 = 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 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
p (3.14) xR
2x H (height) = Cylinder Volume
TEMPERATURE CONVERSION °Cto°F: 9 (°C + 40) ¸5-40=°F
°Fto°C: 5 (°F + 40) ¸9-40=°C
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GENERAL INFORMATION
1.9
SAE TAP DRILL SIZES
Thread Size/Drill Size Thread Size/Drill Size
#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64
1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
11/4-7 17/64
1 1/4-12 1 11/64
11/2-6 111/32
1 1/2-12 1 27/64
13/4-5 19/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
21/2-4 21/4
23/4-4 21/2
3-4 2 3/4
METRIC TAP DRILL SIZES
Tap Size Drill Size Decimal
Equiva-
lent
Nearest
Fraction
3x.50
3x.60
4x.70
4x.75
5x.80
5x.90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75
#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
11/32
R
3/8
13/32
13/32
0.0995
0.0937
0.1285
0.125
0.166
0.161
0.196
0.234
0.277
0.265
0.3125
0.3125
0.3437
0.339
0.375
0.406
0.406
3/32
3/32
1/8
1/8
11/64
5/32
13/64
15/64
9/32
17/64
5/16
5/16
11/32
11/32
3/8
13/32
13/32
DECIMAL EQUIVALENTS
1/64 .0156................
1/32 .0312 1 mm = .0394²........... ...
3/64 .0469................
1/16 .0625...........
5/64 .0781 2 mm = .0787²................ ...
3/32 .0938...........
7/64 .1094 3 mm = .1181².............. ...
1/8. .1250...
9/64 .1406................
5/32 .1563 4 mm = .1575²........... ...
11/64 .1719...............
3/16 .1875 5 mm = .1969²........... ...
13/64 .2031...............
7/32 .2188...........
15/64 .2344 6 mm = .2362²............... ...
1/4 .25....
17/64 .2656 7 mm = .2756²............... ...
9/32 .2813...........
19/64 .2969...............
5/16 .3125 8 mm = .3150²........... ...
21/64 .3281...............
11/32 .3438 9 mm = .3543².......... ...
23/64 .3594...............
3/8 .375....
25/64 .3906 10 mm = .3937²............... ...
13/32 .4063.........
27/64 .4219 11 mm = .4331²............... ...
7/16 .4375...........
29/64 .4531...............
15/32 .4688 12 mm = .4724²......... ...
31/64 .4844...............
1/2 .5 13 mm = .5118.... ..............
33/64 .5156...............
17/32 .5313.........
35/64 .5469 14 mm = .5512²............... ...
9/16 .5625...........
37/64 .5781 15 mm = .5906²............... ...
19/32 .5938.........
39/64 .6094...............
5/8 .625 16 mm = .6299².... ............
41/64 .6406...............
21/32 .6563 17 mm = .6693²......... ...
43/64 .6719..............
11/16 .6875..........
45/64 .7031 18 mm = .7087²............... ...
23/32 .7188.........
47/64 .7344 19 mm = .7480²............... ...
3/4 .75....
49/64 .7656...............
25/32 .7813 20 mm = .7874²......... ...
51/64 .7969...............
13/16 .8125 21 mm = .8268²......... ...
53/64 .8281...............
27/32 .8438.........
55/64 .8594 22 mm = .8661²............... ...
7/8 .875....
57/64 .8906 23 mm = .9055²............... ...
29/32 .9063.........
59/64 .9219..............
15/16 .9375 24 mm = .9449²......... ...
61/64 .9531...............
31/32 .9688 25 mm = .9843......... ...
63/64 .9844...............
11.0.....
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GENERAL INFORMATION
1.10
GLOSSARY OF TERMS
ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
CC: Cubic centimeters.
Center Distance: Distance between center of crankshaft and center of driven clutch shaft.
Chain Pitch: Distance between chain link pins (No. 35 = 3/8²or 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. Measure at various points especially at PTO.
DCV: Direct current voltage.
Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended
load. (i.e. a bare wire touching the chassis).
End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/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/cm 2: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 rotational direction.
lorltr: Liter.
Left Side: Always referred to based on normal operating position of the driver.
m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the windings.
Mechanical energy is converted to electrical energy in the stator.
mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040².
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
Piston Clearance: Total distance between piston and cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
qt.: Quart/quarts.
RPM: Revolutions per minute.
Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy
conversion to heat.
Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder
wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.
Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the circuit.
Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.
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GENERAL INFORMATION
1.11
2003 MODEL YOUTH ATV
SPEED RESTRICTION
Per ANSI / SVIA--1--2001 (sec. 6.1.3)
AS DELIVERED TO THE CONSUMER:
The speed of youth models is restricted
to under 10 MPH for the 50 cc models
and under 15 MPH for the 90 ccmodels.
The dealer CANNOT, under any circum-
stances, either prior to the sale or later,
even at the consumers request,re-
move or adjust any speed limiting device
These are to be adjusted/removed only
by the consumer. Speed limitingdevices
can only be removed or adjusted by the
consumer when they determine their
child is capable of the additional speed.
Per ANSI / SVIA--1--2001 (sec. 6.2) the
unrestricted top speed is less than 15
MPH for the 50 cc models and less than
30 MPH for the 90 cc models.
SPEED CONTROL SYSTEMS
Electronic Speed Control System
YourPolarisATVis equippedwithanelectronicspeed
control system, which controls the engine RPM and
speed of the ATV.
Speed can be adjusted by removing or installing the
jumperontheCDI(A). Withthejumperinstalled,50cc
models will travel no faster than 10 mph and 90cc
models will travel no faster than 15 mph. With the
jumper removed, 50cc models will travel no faster
than15mphand90cc modelswilltravelnofasterthan
30 mph.
Jumper Removal and Installation
1. Remove the CDI and its rubber mounting strap
from the mounting tab, which is located on the
frame bulkhead near the steering post. It can be
accessed through the left front fender.
2. Remove the two screws (B) from the jumper to
remove or install the jumper. Reinstall the
screws.
3. Reinstall the CDI and mounting strap onto the
mounting tab.
A
B
SPEED CONTROL SYSTEMS
Throttle Stop Speed Control System
Adjusting speed at the CDI is the recommended
method of speed control, but the throttle stop system
may also be used. Use the following procedure to
control how far the throttle opens.
1. Loosen the jam nut (A)
2. Turn the screw (B) inward to reduce speed or
outward to increase speed.
3. Tighten the jam nut after adjusting.
AB
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GENERAL INFORMATION
1.12
VEHICLE INSPECTION
FRONT BRAKE
1. Each front brake has a cable connected to the right
hand brake lever.
2. Loosen the adjuster nuts at the right hand brake
lever. Turn the cable adjuster until the proper
brake setting is achieved. Tighten nuts.
Front Brake Lever Free Play:
.40-.80I(10-20 mm)
Front Brake Lever Travel:
50 cc= 1 1/8I(28 mm)
90 cc = 1 3/4²(45 mm)
REAR BRAKE
3. Therearbrakeisoperatedusingtheleft handbrake
lever. To adjust the rear brake setting, turn the
rear brake adjuster nut until brake is set to
specification.
Rear Brake Lever Free Play:
.40-.80I(10-20 mm)
Rear Brake Lever Travel:
50 cc= 1 1/8I(28 mm)
90 cc = 2 1/2²(65 mm)
VEHICLE INSPECTION
CHAIN ADJUSTMENT
1. Remove the rear cover and loosen the four bearing
housing bolts.
Chain Tension Specification:
1/4-1/2²(10-20 mm) Deflection
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GENERAL INFORMATION
1.13
2. Loosen the four bearing housing bolts. Loosen the
chain adjuster lock nut. Turn the chain adjuster
clockwise until chain is set to specification
1/4”--1/2” (6--12 mm). Tighten the chain adjuster
lock nut to specification.
Chain Adjuster Lock Nut Torque:
84 in.lbs (9.4 Nm)
3. Tighten the four bearing housing bolts to
specification. Re-install rear cover.
Bolts
Bearing Housing Bolt Torque:
43 ft.lbs (60 Nm)
LUBRICATION
1. Lubricate grease fittings on spindles monthly with
Polaris All Season Grease, or more frequently if
used often.
Polaris Premium All Season Grease
14 oz. (PN 2871423)
Grease Gun Kit PN 2871312
FRONT SHOCKS AND SPRINGS
1. Inspect the front shocks and springs to ensure
proper function. If the shock is leaking oil,
replace. The spring preload can be adjusted on
the Sportsman 90 by turning the adjuster nut.
Inspect the A-arm and weldments for any sign
damage.
REAR SHOCK AND SPRING
1. Inspect the rear shock and spring to ensure proper
function. If the shock is leaking oil, replace.
Inspect the swing arm and weldments for any sign
of damage.
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GENERAL INFORMATION
1.14
VEHICLE INSPECTION CONT’D
WHEEL NUTS
2. Inspect the front and rear wheel nuts for tightness.
Re-torque wheel nuts monthly to specification.
Wheel Nut Torque:
22-29ft.lbs(30-40Nm)
TRANSMISSION
LUBRICATION
The transmission lubricant level should be checked
and changed in accordance with the maintenance
schedule.
Remember to:
GBe sure vehicle is level before
proceeding.
GCheck vent hose to be sure it is
routed properly and unobstructed.
GFollow instructions to check /
change transmission lubricant.
Fill Plug
Specified Lubricant:
Polaris Premium Synthetic Gearcase Lubricant
(PN 2871477) (Gallon) (PN 2871478) (12 oz..)
Capacity:10 fl.oz. / 300 ml.
Capacity at Change: ..... 7 oz. / 200ml
Operating Range: Oil level visible in sight
glass safe zone.
Drain Plug Torque:
14 ft. lbs. (19.4 Nm)
TRANSMISSION SPECIFICATIONS
To check the level:
The gearcase fill plug (A) is located on the top of the
gearcase. Thesightglass(B)isontheright-handside
of the gearcase. The oil level must be maintained in
the safe zone of the sight glass. 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
Premium Synthetic Gearcase Lubricant. See page
1.6 for the part numbers of Polaris-recommended
products.
B
A
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GENERAL INFORMATION
1.15
To change lubricant:
1. Place a drain pan beneath the transmission
lubricant drain plug area.
2. Remove the drain plug and wipe the magnetic end
clean to remove accumulated metallic filings.
Vent Hose
Drain Plug
3. After the lubricant has drained completely, install a
new sealing washer and install the drain plug.
Torque to 14 ft. lbs. (19.3 Nm).
4. Add the proper lubricant through the fill plug hole. Do
not overfill. An indication of over filling is lubricant
leaking from the vent hose after operation.
5. Check for leaks. Discard used lubricant properly.
THROTTLE OPERATION
Check for smooth throttle opening and closing.
Throttle lever operation should be smooth and lever
must return freely without binding.
1. Start the engine and let it idle.
2. Turn handlebars from full right to full left. If idle
speed increases at any point in the turning range,
inspect throttle cable routing and condition.
3. Replace the throttle cable if worn, kinked, or
damaged.
AIR SCREW ADJUSTMENT
1. Turn carburetor air screw in (clockwise) until lightly
seated. Back screw out the specified number of
turns.
Air Screw
Air Screw Adjustment:
50 cc: 1/2 Turn Out from Lightly Seated
90 cc: 1 Turn Out from Lightly Seated
2. Warm up the engine to operating temperature
(about 10 minutes).
3. Set idle speed to 800 RPM.
NOTE: Adjustingtheairscrewmayaffect idlespeed.
Always check throttle cable freeplay after adjusting
idle speed and adjust if necessary.
4. Turn the screw in (to richen) or out (to lean) the
mixture. Adjust air screw for best throttle
response and smooth idle.
5. Re-adjust idle speed if necessary.
IDLE SPEED ADJUSTMENT
1. Start engine and warm it up thoroughly.
Throttle Set Screw
2. Adjust idle speed by turning the idle adjustment
screw in (clockwise) to increase or out
(counterclockwise) to decrease RPM.
Idle Speed:
800 ±200 RPM
NOTE: Adjusting the idle speed affects throttle cable
freeplay and electronic throttle control (ETC)
adjustment. Always check throttle cable freeplay
after adjusting idle speed and adjust if necessary.
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GENERAL INFORMATION
1.16
CHOKE (ENRICHER)
ADJUSTMENT
2003 Youth ATVs are fitted with a new manual choke
system. Adjust the choke tension by tightening the
tensioner located under the rubber boot between the
chokeknobandnut. Firmlygrasptherubber bootand
tightenuntilthechoke slidesfreely butstaysout when
pulled.
Boot
Verify free play of 1/16--3/16” (1.6--4.76 mm) and
smooth operation of choke cable.
If smooth choke operation is not obtainable, inspect
choke cable for kinks or sharp bends in routing.
THROTTLE CABLE /
ELECTRONIC THROTTLE
CONTROL (ETC SWITCH)
ADJUSTMENT
1. Slide boot off throttle cable adjuster and jam
nut.
Boot Lock-
nut
Ill. 1
2. Set parking brake.
3. Start engine and set idle to specified RPM.
NOTE: Be sure the engine is at operating
temperature. See Idle Speed Adjustment.
4. Loosen lock nut on in-line cable adjuster (Ill. 1).
5. Turn cable adjuster out until engine RPM begins to
increase.
6. Turn cable adjuster back in until throttle lever has
1/16²(.16 cm) of travel before engine RPM
increases.
7. Tighten lock nut securely and slide boot completely
in place to ensure a water-tight seal.
Switch Plunger Must
Be Held In By Cable
Tension
Ill. 2
Throttle Cable
Adjuster Lock Nut
NOTE: Be sure ETC switch plunger is held inward by
throttlecabletension(seeIll.2).
NOTE: Whenever throttle cable adjustments are
made, always check oil pump adjustment and
re-adjust if necessary.
1/16²-1/8²
Freeplay
Direction
of travel
Ill. 3
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