2003 POLARIS PREDATOR 90 SPORTSMAN 90 Service Manual

SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 SERVICE MANUAL PN 9918068 The Way Out.

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. 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. 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.

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 to follow DANGER instructions will result in severe injury or death to the operator, bystander or person 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

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 / MAINTENANC E 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 ..........................

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION 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 03 EA 05 CA Emissions & Model Option VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 R F 3 E A 0 5 C * 3 T 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 SERIAL NUMBER LOCA TIONS 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

GENERAL INFORMATION 1.3 2003 YOUTH MODEL A TVS SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 NOTE: Colors will vary upon model.

GENERAL INFORMATION 1.4

GENERAL INFORMATION 1.5 SPECIFICA TIONS MODEL SCRAMBLER 50 SCRAMBLER 90 PREDATOR 90 SPORTSMAN 90 ENGINE TYPE 2-Stroke Horizontal (AR03--01) 2-Stroke Horizontal (AR07--01) 2-Stroke Horizontal (AR07--01) 2-Stroke Horizontal (AR07--01) NUMBER OF CYLINDERS 1 1 1 1 DISPLACEMENT 49.3 cc 89.2 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) 2.05x1.65 (52x42 mm) COMPRESSION RATIO 6.8:1 7.7:1 7.7:1 7.7:1 SPARK PLUG BPR7HS BPR7HS BPR7HS BPR7HS ALTERNATOR OUTPUT 70 Watts @ 4000 RPM 70 Watts @ 4000 RPM 70 Watts @ 4000 RPM 70 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 1.057 Quarts (1 Liter) 1.057 Quarts (1 Liter) 1.057 Quarts (1 Liter) 1.057 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 4.25 (10.8 cm) Travel A-arm with 4.25 (10.8 cm) Travel A-arm with 4.25 (10.8 cm) Travel A-arm with 4.25 (10.8 cm) Travel REAR SUSPENSION Single Shock/Swing Arm with 4.25 (10.8 cm) Travel Single Shock/Swing Arm with 4.25 (10.8 cm) Travel Single Shock/Swing Arm with 4.25 (10.8 cm) Travel Single Shock/Swing Arm with 4.25 (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 16x8-7 18x7-7 18x7-7 19x7-8 REAR TIRES 16x8-7 18x9.5-8 18x9.5-8 18x9.5-8 TIRE PRESSURE 2 psi 3 psi 3 psi 3 psi OVERALL DIMENSIONS 54.6x34x34.7 (138.7x86.3x88.2 cm) 57x35.75x36 (145x91x91.8 cm) 57x35.75x36 (145x91x91.8 cm) 57x35.75x36 (145x91x91.8 cm) WHEELBASE 35.4 (90 cm) 38.5 (98 cm) 38.5 (98 cm) 38.5 (98 cm) TURNING RADIUS 74.8 (190 cm) 98.4 (250 cm) 98.4 (250 cm) 98.4 (250 cm) SEAT HEIGHT 22.5 (57 cm) 24.5 (62 cm) 24.5 (62 cm) 24.5 (62 cm) GROUND CLEARANCE 3 (8 cm) 4 (10 cm) 4 (10 cm) 5 (12 cm) DRY WEIGHT 211.6 lbs. (96 kg) 233.7 lbs. (106 kg) 233.7 lbs. (106 kg) 238.1 lbs. (108 kg) MAX. LOAD CAPACITY 100 lbs. (45.4 kg) 160 lbs. (72 kg) 160 lbs. (72 kg) 190 lbs. (86 kg) FUEL REQUIREMENTS 87 Octane Unleaded 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) 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)*

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 9917873 9917875 9917876 Sportsman 90 A03FA09 9917873 9917885 9917886 Scrambler 90 A03EA09 9917873 9917880 9917881 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-067 Scrambler 90 Springs Yellow N/A P-216 Predator 90 Springs Indy Red N/A P-293 Frame -- All Medium Gloss Black 9440 P-067 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.

2003 POLARIS PREDATOR 90 SPORTSMAN 90 Service Manual

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