POLARIS SCRAMBLER 50 90 Service Repair Manual 2001-2002

1 CHAPTER 1 GENERAL INFORMATION Model Identification 1.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial Number Location 1.1 . . . . . . . . . . . . . . . . . . . . . . . Specifications - General 1.2 . . . . . . . . . . . . . . . . . . . . . . . Publication Numbers 1.3 . . . . . . . . . . . . . . . . . . . . . . . . . . Paint Codes 1.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Torque Specifications 1.4 . . . . . . . . . . . . . . . . . Lubricant and Maintenance Part Numbers 1.4 . . . . . . . Torque Conversion Table 1.5-1.6 . . . . . . . . . . . . . . . . . . . . . . Decimal Equivalent Chart 1.7 . . . . . . . . . . . . . . . . . . . . . . Unit of Measure Conversion Table 1.8 . . . . . . . . . . . . . . Tap Drill Charts 1.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary of Terms 1.10-1.11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection Schedule 1.12 . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Inspection 1.13-1.15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Lubrication 1.16 . . . . . . . . . . . . . . . . . . . . . . Throttle Operation / Air Screw Adjustment 1.17 . . . . . . . Idle Speed Adjustment 1.18 . . . . . . . . . . . . . . . . . . . . . . . . Throttle Cable Adjustment 1.18-1.19 . . . . . . . . . . . . . . . . . . . . . Oil Pump Adjustment / Bleeding 1.20 . . . . . . . . . . . . . . . . Oil Pump Troubleshooting 1.21 . . . . . . . . . . . . . . . . . . . . . Fuel System 1.22-1.23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compression Test 1.24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter Service 1.24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires 1.25-1.26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alignment 1.27-1.28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL INFORMATION 1.1 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 A 0 1 E A 0 5 C A Emissions & Model Option VIN IDENTIFICATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4 X A E A 0 5 A * 1 P 0 0 0 0 0 0 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No. Individual Serial No. Body Style Check Digit World Mfg. ID * This could be either a number or a letter ENGINE SERIAL NUMBER LOCATION Whenever corresponding about an engine, be sure to refer to the engine model number and serial number. This information can be found stamped on the transmission section located by the transmission oil fill plug(A). MACHINE SERIAL NUMBER LOCATION The machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the front of the frame tube(B). Front B A

GENERAL INFORMATION 1.2 SPECIFICATIONS MODEL SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 ENGINE TYPE 2-Stroke Horizontal 2-Stroke Horizontal 2-Stroke Horizontal NUMBER OF CYLINDERS 1 1 1 DISPLACEMENT 49.3 cc 89.2 cc 89.2 cc BORE AND STROKE 1.58x1.54″ (40x39.2 mm) 2.05x1.65″ (52x42 mm) 2.05x1.65″ (52x42 mm) COMPRESSION RATIO 6.8:1 5.8:1 5.8:1 ALTERNATOR OUTPUT 70 Watts @ 4000 RPM 70 Watts @ 4000 RPM 70 Watts @ 4000 RPM IGNITION TIMING 14° @ 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 CARBURETOR Mikuni AM3 with automatic choke Mikuni AM7 with automatic choke Mikuni AM7 with automatic choke STARTING Electric/Kick Start Electric/Kick Start Electric/Kick Start BATTERY 12N4-3B, 4 milliamp 12N4-3B, 4 milliamp 12N4-3B, 4 milliamp LUBRICATION Oil Injection Oil Injection Oil Injection OIL CAPACITY 1.057 Quarts (1 Liter) 1.057 Quarts (1 Liter) 1.057 Quarts (1 Liter) TRANSMISSION Automatic (C.V.T. System) Automatic (C.V.T. System) Automatic (C.V.T. System) FRONT SUSPENSION A-arm with 2″ (5 cm) Travel A-arm with 2″ (5 cm) Travel A-arm with 2″ (5 cm) Travel REAR SUSPENSION Single Shock/Swing Arm with 2″ (5 cm) Travel Single Shock/Swing Arm with 2″ (5 cm) Travel Single Shock/Swing Arm with 2″ (5 cm) Travel FRONT BRAKE Drum Drum Drum REAR BRAKE Drum Drum Drum PARKING BRAKE Mechanical Lock Mechanical Lock Mechanical Lock FRONT TIRES 16x8-7 18x7-7 19x7-8 REAR TIRES 16x8-7 18x7-7 18x9.5-8 TIRE PRESSURE 2 psi 2 psi 2 psi OVERALL DIMENSIONS 54x34x34.7″ (137.1x86.4x88.1 cm) 56.1x34x36.1″ (142.4x86.3x91.8 cm) 57.6x34.4x36.6″ (146.3x87.4x93 cm) WHEELBASE 35.4″ (90 cm) 35.4″ (90 cm) 37.8″ (96 cm) TURNING RADIUS 74.8″ (190 cm) 98.4″ (250 cm) 98.4″ (250 cm) SEAT HEIGHT 22.5″ (57 cm) 24.5″ (62 cm) 24.5″ (62 cm) GROUND CLEARANCE 3″ (8 cm) 4″ (10 cm) 5″ (12 cm) DRY WEIGHT 211.6 lbs. (96 kg) 233.7 lbs. (106 kg) 238.1 lbs. (108 kg) MAX. LOAD 100 lbs. (45.4 kg) 160 lbs. (72 kg) 190 lbs. (86 kg) FUEL REQUIREMENTS 87 Octane Unleaded 87 Octane Unleaded 87 Octane Unleaded FUEL CAPACITY 1.32 Gallons (5 Liters) 1.32 Gallons (5 Liters) 1.32 Gallons (5 Liters) FRONT RACK CAPACITY N/A N/A 10 lbs. (4.54 kg)* REAR RACK CAPACITY N/A N/A 20 lbs. (9.08 kg)* * Check owner’s manual for loading requirements and restrictions.

GENERAL INFORMATION 1.3 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN Service Manual 2001 Scrambler 50 A01EA05CA 9916424 9916426 9916427 9916576 2001 Sportsman 90 A01FA09CA 9916424 9916762 9916763 9916576 2001 Scrambler 90 A01EA09CA 9916424 9916432 9916433 9916576 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DESCRIPTION DITZLER NUMBER POLARIS NUMBER 2001 Scrambler 50 Springs Fire Red 72060 P-093 2001 Sportsman 90 Springs Fire Red 72060 P-093 2001 Scrambler 90 Springs Fire Red 72060 P-093 FRAME COLOR - (All) P067 Medium Gloss Black 9440 / 8520147. Order direct from Midwest Industrial Coatings (763-942-1840). Mix as directed.

GENERAL INFORMATION 1.4 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. 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 6 mm Hex bolts 87-121 in.lbs. 10-14 Nm 8 mm Hex bolts 17-22 ft.lbs. 24-30 Nm 10 mm Hex bolts 25-32 ft.lbs. 35-45 Nm POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD- UCT PART NUMBERS 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 Grease Gun Kit 2871329 Nyogelt Grease Additives / Sealants / Thread Locking Agents / Misc. 2871326 Premium Carbon Clean 12 oz.. 2870652 Fuel Stabilizer 16 oz..

Newton Meter to Pound Foot and Pound Inch GENERAL INFORMATION 1.5 TORQUE CONVERSIONS

Newton Meter to Pound Foot and Pound Inch GENERAL INFORMATION 1.6 TORQUE CONVERSIONS

GENERAL INFORMATION 1.7 DECIMAL EQUIVALENTS 1/64 .0156 . . . . . . . . . . . . . . . . . . . . . . . . . 1/32 .0312 1 mm = .0394″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/64 .0469 . . . . . . . . . . . . . . . . . . . . . . . . . 1/16 .0625 . . . . . . . . . . . . . . 5/64 .0781 2 mm = .0787″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/32 .0938 . . . . . . . . . . . . . . . . . . . 7/64 .1094 3 mm = .1181″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8 . .1250 . . . . . . . . 9/64 .1406 . . . . . . . . . . . . . . . . . . . . . . . . . 5/32 .1563 4 mm = .1575″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/64 .1719 . . . . . . . . . . . . . . . . . . . . . . . . 3/16 .1875 5 mm = .1969″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/64 .2031 . . . . . . . . . . . . . . . . . . . . . . . 7/32 .2188 . . . . . . . . . . . . . . . . . . . 15/64 .2344 6 mm = .2362″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 .25 . . . . . . . . . . 17/64 .2656 7 mm = .2756″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/32 .2813 . . . . . . . . . . . . . . . . . . . 19/64 .2969 . . . . . . . . . . . . . . . . . . . . . . . 5/16 .3125 8 mm = .3150″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21/64 .3281 . . . . . . . . . . . . . . . . . . . . . . . 11/32 .3438 9 mm = .3543″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/64 .3594 . . . . . . . . . . . . . . . . . . . . . . . 3/8 .375 . . . . . . . . . . 25/64 .3906 10 mm = .3937″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13/32 .4063 . . . . . . . . . . . . . . . . . . 27/64 .4219 11 mm = .4331″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/16 .4375 . . . . . . . . . . . . . . 29/64 .4531 . . . . . . . . . . . . . . . . . . . . . . . 15/32 .4688 12 mm = .4724″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31/64 .4844 . . . . . . . . . . . . . . . . . . . . . . . 1/2 .5 13 mm = .5118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33/64 .5156 . . . . . . . . . . . . . . . . . . . . . . . 17/32 .5313 . . . . . . . . . . . . . . . . . . 35/64 .5469 14 mm = .5512″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9/16 .5625 . . . . . . . . . . . . . . 37/64 .5781 15 mm = .5906″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19/32 .5938 . . . . . . . . . . . . . . . . . . 39/64 .6094 . . . . . . . . . . . . . . . . . . . . . . . 5/8 .625 16 mm = .6299″ . . . . . . . . . . . . . . . . . . . . . . . . . . . 41/64 .6406 . . . . . . . . . . . . . . . . . . . . . . . 21/32 .6563 17 mm = .6693″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43/64 .6719 . . . . . . . . . . . . . . . . . . . . . . . 11/16 .6875 . . . . . . . . . . . . . 45/64 .7031 18 mm = .7087″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23/32 .7188 . . . . . . . . . . . . . . . . . . 47/64 .7344 19 mm = .7480″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 .75 . . . . . . . . . . 49/64 .7656 . . . . . . . . . . . . . . . . . . . . . . . 25/32 .7813 20 mm = .7874″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51/64 .7969 . . . . . . . . . . . . . . . . . . . . . . . 13/16 .8125 21 mm = .8268″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53/64 .8281 . . . . . . . . . . . . . . . . . . . . . . . 27/32 .8438 . . . . . . . . . . . . . . . . . . 55/64 .8594 22 mm = .8661″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7/8 .875 . . . . . . . . . . 57/64 .8906 23 mm = .9055″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29/32 .9063 . . . . . . . . . . . . . . . . . . 59/64 .9219 . . . . . . . . . . . . . . . . . . . . . . . 15/16 .9375 24 mm = .9449″ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61/64 .9531 . . . . . . . . . . . . . . . . . . . . . . . 31/32 .9688 25 mm = .9843 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63/64 .9844 . . . . . . . . . . . . . . . . . . . . . . . 1 1.0 . . . . . . . . . . .

GENERAL INFORMATION 1.8 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 Nm x .7376 = ft.lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 10 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 = cm mile (mi.) x 1.6 = 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) 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 = 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) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa) π (3.14) x R 2 x H (height) = Cylinder Volume °C to °F: 9 (°C + 40) ÷ 5 - 40 = °F °F to °C: 5 (°F + 40) ÷ 9 - 40 = °C

POLARIS SCRAMBLER 50 90 Service Repair Manual 2001-2002

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