Page 1: Table Of Contents
CHAPTER 1 GENERAL INFORMATION Model Identification ......Serial Number Location ..... . . Specifications - General .
Page 3: General Information
GENERAL INFORMATION MODEL IDENTIFICATION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification A 0 1 E A 0 5 C A Emissions & Model Option Year Designation Basic Chassis Designation Engine Designation VIN IDENTIFICATION World Mfg.
Page 4: Specifications
GENERAL INFORMATION SPECIFICATIONS MODEL SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 ENGINE TYPE 2-Stroke Horizontal 2-Stroke Horizontal 2-Stroke Horizontal NUMBER OF CYLINDERS 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...
Page 5: Publication Numbers
9916424 9916432 9916433 9916576 When ordering service parts be sure to use the correct parts manual. PAINT CODES PAINTED PART COLOR DITZLER POLARIS DESCRIPTION NUMBER NUMBER 2001 Scrambler 50 Springs Fire Red 72060 P-093 2001 Sportsman 90 Springs Fire Red...
Page 6: Standard Torque Specifications
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)
Page 7 GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch...
Page 8 GENERAL INFORMATION TORQUE CONVERSIONS Newton Meter to Pound Foot and Pound Inch...
Page 9: Decimal Equivalents
GENERAL INFORMATION DECIMAL EQUIVALENTS 1/64 ......0156 1/32 ....0312 .
Page 10: Conversion Table
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 11: Decimal Equivalent Chart
GENERAL INFORMATION SAE TAP DRILL SIZES Thread Size Drill Size Thread Size Drill Size #0-80 3/64 1/2-13 27/64 #1-64 1/2-20 29/64 #1-72 9/16-12 31/64 #2-56 9/16-18 33/64 #2-64 5/8-11 17/32 #3-48 5/64 5/8-18 37/64 #3-56 3/4-10 21/32 #4-40 3/4-16 11/16 #4-48 7/8-9 49/64...
Page 12: Glossary Of Terms
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 = 3/8″ or 1 cm). Polaris measures chain length in number of pitches. CI: Cubic inches.
Page 13 Piston Clearance: Total distance between piston and cylinder wall. psi.: Pounds per square inch. PTO: Power take off. PVT: Polaris Variable Transmission (Drive Clutch System) qt.: Quart/quarts. RPM: Revolutions per minute. Regulator: Voltage regulator. Regulates battery charging system output at approx. 14.5 DCV as engine RPM increases.
Page 14: Inspection Schedule
GENERAL INFORMATION INSPECTION SCHEDULE Service Item Initial Service Monthly Every 6 Months Yearly (After two weeks) Air Cleaner Fuel Filter Fuel/Oil Lines Battery Brake Shoes Spark Plug Chain Lubrication Steering Lubrication Carburetor Throttle Control Tire Pressure Fasteners Gear Oil R = Replace C = Clean T =Tighten I = Inspect...
Page 15: Vehicle Inspection
GENERAL INFORMATION 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:...
Page 16 Bearing Housing Bolt Torque: 43 ft.lbs (60 Nm) Bolts Lubrication 4. 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...
Page 17 GENERAL INFORMATION VEHICLE INSPECTION 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.
Page 18: Transmission Lubrication
Check vent hose to be sure it is routed properly and unobstructed. Follow instructions on following pages to check / change transmission lubricant. TRANSMISSION SPECIFICATIONS Specified Lubricant: Polaris Premium Synthetic Gearcase Lubricant PN 2871477 (Gallon) PN 2871478 (12 oz..) Capacity: ..
Page 19: Throttle Operation / Air Screw Adjustment
GENERAL INFORMATION THROTTLE OPERATION Check for smooth throttle opening and closing in all han- dlebar positions. 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.
Page 20: Idle Speed Adjustment
GENERAL INFORMATION IDLE SPEED ADJUSTMENT 1. Start engine and warm it up thoroughly. 2. Adjust idle speed by turning the idle adjustment screw in (clockwise) to increase or out (counterclockwise) to decrease RPM. (Refer to Ill. at right). Idle NOTE: Adjusting the idle speed affects throttle cable Screw freeplay and electronic throttle control (ETC) adjustment.
Page 21 GENERAL INFORMATION THROTTLE CABLE / ELECTRONIC THROTTLE CONTROL (ETC SWITCH) ADJUSTMENT, CONT. NOTE: Whenever throttle cable adjustments are made, always check oil pump adjustment and re-adjust if neces- sary. 8. Turn handlebars from left to right through the entire turning range. If idle speed increases, check for proper cable routing.
Page 22 8. Replace oil pump adjuster covers. OIL PUMP BLEEDING PROCEDURE 1. Fill the oil reservoir with Polaris injector oil. 2. Loosen the pump bleed screw one full turn. Allow Bleed Screw oil to flow from the bleed screw for five to ten seconds.
Page 23: Oil Pump Troubleshooting
GENERAL INFORMATION OIL PUMP TROUBLESHOOTING PROCEDURE To verify oil delivery to engine, proceed as follows: 1. Premix fuel in tank at a 40:1 fuel/oil ratio. 2. With the oil reservoir full and the pump bled, remove the oil delivery line from the intake manifold. 3.
Page 24: Fuel System
GENERAL INFORMATION FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 25: Carburetor Draining
GENERAL INFORMATION CARBURETOR DRAINING The carburetor float bowl should be drained periodically to remove moisture or sediment from the bowl, or before ex- tended periods of storage. NOTE: A drain plug is located on the side of the float bowl. 1.
Page 26: Compression Test
GENERAL INFORMATION COMPRESSION TEST 1. Remove spark plug and install compression tester. 2. Connect high tension lead to a good ground on engine. 3. Open throttle and crank engine until maximum reading is obtained (approximately 3-5 revolutions). Cylinder Compression Service Limit 115 PSI AIR FILTER SERVICE 1.
Page 27: Wheel Removal Front Or Rear
GENERAL INFORMATION WHEELS Inspect all wheels for runout or damage. Check wheel bolts and ensure they are tight. Do not over tighten the wheel bolts. WHEEL, HUB, AND SPINDLE TORQUE TABLE Item Specification Front Wheel Bolts 22-29 Ft. Lbs. (30-40 Nm) Rear Wheel Bolts 22-29 Ft.
Page 28: Tire Pressure
GENERAL INFORMATION TIRE PRESSURE Tire Pressure Inspection (PSI - Cold) Front Rear TIRE INSPECTION CAUTION: Maintain proper tire pressure. Refer to the tire pressure warning decal applied to the vehicle. Tread Improper tire inflation may affect ATV maneuverability. Depth 1/8I (3 mm) When replacing a tire always use original equipment size and type.
Page 29 GENERAL INFORMATION TOE ALIGNMENT - METHOD 1: STRAIGHTEDGE OR STRING Be sure to keep handlebars centered. See note below. NOTE: String should just touch side surface of rear tire on each side of machine. Measure from string to rim at front and rear of rim.
Page 30: Alignment
GENERAL INFORMATION TOE ALIGNMENT - METHOD 2 CHALK 1. Place machine on a smooth level surface. 2. Set handlebars in a straight ahead position and secure handlebars in this position. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight.
Page 31 CHAPTER 2 ENGINE Torque Specifications ......Special Tools, Engine ......Engine Installation Notes .
Page 33: Torque Specifications
ENGINE TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Fastener Torque Carburetor Adaptor 20 in.lbs (2.25 Nm) Crankcase 86 in.lbs (10 Nm) Intake Manifold Bolts 108 in.lbs (12 Nm) Cylinder Head Nuts 14 ft.lbs (19 Nm) Drive Clutch Nut 29 ft.lbs (39 Nm) Driven Clutch Nut Torque 25 ft.lbs (34 Nm) Transmission Cover Bolts 84 in.lbs (9.5 Nm)
Page 34: Engine Installation Notes
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 35: Engine Disassembly
ENGINE ENGINE DISASSEMBLY Fan Cover and Cylinder Air Shroud 1. Remove the fasteners on fan cover. 2. Remove cylinder air shroud and deflector. 3. Loosen bolts securing fan and remove fan. Starter Motor 4. Remove starter motor.
Page 36 ENGINE ENGINE DISASSEMBLY, CONT. Inlet and Fuel System 5. Slide air box-to-carburetor air clip out of the way and remove air duct. 6. Loosen carburetor adaptor screw and remove carburetor. 7. Remove bolts securing the intake manifold. Remove intake manifold and reed valve. NOTE:Remove any remaining gasket material from the reed valve housing and crankcase.
Page 37 ENGINE ENGINE DISASSEMBLY, CONT. 9. Remove cylinder head nuts and remove cylinder head. Clean the head using parts washer solvent. NOTE:Always replace head gasket with new. 10. Remove cylinder. Clean the carbon from the cylinder walls and ports using parts washer solvent. Inspect the cylinder walls for signs of scoring.
Page 38 ENGINE ENGINE DISASSEMBLY, CONT. 13. Carefully remove piston rings so no damage is done to the ring lands. Discard rings and replace with new. 14. Remove small end bearing from connecting rod. Transmission System 15. Loosen and remove all bolts, protectors, carburetor tube bracket, and cover (Scrambler 50).
Page 39 ENGINE ENGINE DISASSEMBLY, CONT. 16. Remove kick starter, bolts, grommets, protectors, filter, and remove carburetor tube bracket and crankcase cover (Sportsman 90 and Scrambler 90). Remove gasket and discard. 17. Remove drive clutch nut. 18. Remove one-way clutch washer. 19. Remove the primary fixed sheave and claw washer.
Page 40 ENGINE ENGINE DISASSEMBLY, CONT. 20. Remove belt. 21. Remove primary clutch sheave. 22. Remove the nut on driven clutch and remove clutch assembly. NOTE:Be careful not to lose the oil ring upon removal. Starter Clutch Set 23. Remove idle gear bolts. 24.
Page 41 ENGINE ENGINE DISASSEMBLY, CONT. 25. Remove the starter clutch, starter gear, needle bearing, and washer. Driven Shaft Assembly 26. Drain the oil from gear case. Drain Plug 27. Remove transmission cover and gasket. 28. Remove the driven clutch shaft components and shaft assembly.
Page 42 ENGINE ENGINE DISASSEMBLY, CONT. Stator Assembly 29. Remove flywheel nut and washer. 30. Remove the flywheel using flywheel puller. Flywheel Puller: PN 0450698 31. Scribe an alignment mark on the stator backing plate and the crankcase for proper alignment upon engine assembly.
Page 43 ENGINE ENGINE DISASSEMBLY, CONT. Oil Pump 32. Remove stator gasket, clean the area thoroughly. Loosen bolts and remove the oil pump. 33. Remove external circlips and use a special tool to remove the oil pump drive gear. Oil Pump Drive Gear Removal Tool: PN 0450699 34.
Page 44 ENGINE ENGINE DISASSEMBLY, CONT. Crankcase 35. Remove all crankcase bolts. Use a special tool to disassemble the right and left crankcase halves. Crankcase Separating Tool: PN 0450700 36. Use a special tool to remove the crankshaft. Crankshaft Removal Tool: PN 0450697 37.
Page 45: Engine Inspection
ENGINE ENGINE INSPECTION PROCEDURES Cylinder Head Inspection 1. Inspect the surface of the cylinder head for warpage. Clean all gasket residue completely from sealing surface. Use a feeler gauge and straight edge. Measure the gap six(6) different ways as shown in illustration at left. Normal gap should be .002″...
Page 46 ENGINE ENGINE INSPECTION PROCEDURES, CONT. Piston Ring Installed Gap 1. Position piston ring 1/2″ (1.3 cm) from the top of the cylinder using the piston to push it squarely into place. Measure installed gap with a feeler gauge at both the top and bottom of the cylinder. Replace rings if the installed end gap exceeds the service limit.
Page 47 ENGINE ENGINE INSPECTION PROCEDURES, CONT. Reed Valve Inspection 1. Measure the air gap between fiber reed and reed block as shown. The air gap should not exceed .015″ (.40 mm) If clearance is excessive DO NOT Reed Pedal Exaggerated attempt to reverse the reeds to reduce the air gap. Clearance .015″...
Page 48: Honing To Oversize
Selecting a hone which will straighten as well as remove material from the cylinder is very important. Using a common spring loaded finger type glaze breaker for honing is never advised. Polaris recommends using a rigid hone or arbor honing machine which also has the capability of oversizing.
Page 49: Crankshaft Runout Inspection
ENGINE CRANKSHAFT RUNOUT Lubricate the bearings and clamp the crankshaft securely in the holding fixture. Refer to the illustrations below. Crankshaft Alignment Fixture PN 2870569 1. If the runout of the crankshaft is more than .004″ (.100mm) on the MAG side, or .006″ (.150mm) on the PTO side, the crankshaft must be replaced.
Page 50: Engine Assembly
ENGINE ENGINE ASSEMBLY Crankcase 1. Install a new output shaft oil seal and replace the snap ring. 2. Install the crankshaft in one of the crankcase halves. Install a new crankcase gasket and install the other side of the crankcase. Torque the crankcase bolts to specification.
Page 51 ENGINE ENGINE ASSEMBLY 5. Make sure oil pump area is clean. Install oil pump and torque to specification. Install new stator gasket. Oil Pump Bolt Torque: 43 in.lbs. (5 Nm) 6. Install stator. Torque bolts to specification. Stator Mounting Bolt Torque: 84 in.lbs.
Page 52 10. Add the specified amount of oil to the transmission gear case. Inspect for leaks. Gear Case Oil Specification: 10 fl.oz. (300 ml) Polaris Premium Synthetic Gearcase Lubricant: PN 2871477 (Gallon) PN 2871478 (12 oz.) 11. Install the starter clutch, starter gear, needle bearing, and washer.
Page 53 ENGINE ENGINE ASSEMBLY 14. Install oil ring, driven clutch, and driven clutch nut on output shaft. Torque nut to specification Driven Clutch Nut Torque: 25 ft.lbs. (34 Nm) 15. Install primary clutch sheave. 16. Install drive belt. 17. Install the primary fixed sheave and claw washer. 2.21...
Page 54 ENGINE ENGINE ASSEMBLY 18. Install drive clutch bolt and torque to specification. Drive Clutch Nut Torque: 29 ft.lbs. (39 Nm) 19. Install new gasket, bolts, grommets, protectors, filter and install carburetor tube bracket and crankcase cover (Sportsman 90 and Scrambler 90). Torque cover bolts to specification.
Page 55 ENGINE ENGINE ASSEMBLY 21. Install small end bearing into connecting rod. 22. Carefully install new piston rings so no damage is done to the piston or ring lands. 23. Install new base gasket and carefully install new piston and piston pin. Use care not to damage parts.
Page 56 ENGINE ENGINE ASSEMBLY 25. Make sure cylinder is clean and free of debris. Install cylinder carefully making sure the piston rings are in the correct position. 26. Install a new head gasket and install head. Torque the cylinder head in a criss-cross patten to specification. Cylinder Head Nut Torque: 14 ft.lbs.
Page 57 ENGINE ENGINE ASSEMBLY 29. Install carburetor and tighten the carburetor adaptor screw to specification. Carburetor Adaptor Screw Torque: 20 in.lbs. (2.25 Nm) 30. Install air duct to carburetor. 31. Install starter motor. Torque bolts to specification. Starter Motor Bolt Torque: 84 in.lbs.
Page 58 ENGINE ENGINE ASSEMBLY 33. Install cylinder air shroud and deflector. Cylinder Air Shroud and Deflector Screw Torque: 84 in.lbs. (9.5 Nm) 34. Install fasteners on fan cover and torque bolts to specification. 2.26...
Page 59: Spark Plug Fouling
ENGINE SPARK PLUG FOULING Spark plug cap loose or faulty Choke cable adjustment or plunger/cable sticking Foreign material on choke plunger seat or plunger Incorrect spark plug heat range or gap Carburetor inlet needle and seat worn or leaking Jet needle and/or needle jet worn or improperly adjusted Excessive carburetor vibration (loose or missing needle jet locating pins) Loose jets in carburetor or calibration incorrect for altitude/temperature Incorrect float level setting...
Page 60 ENGINE TROUBLESHOOTING Engine Turns Over But Fails to Start No fuel Dirt in fuel line or filter Fuel will not pass through fuel valve Fuel pump inoperative/restricted Tank vent plugged Carb starter circuit Engine flooded Low compression (high cylinder leakage) No spark (Spark plug fouled) Engine Does Not Turn Over Dead battery...
Page 61 ENGINE TROUBLESHOOTING, CONT Excessive Smoke and Carbon Buildup Excessive piston-to-cylinder clearance Worn rings, piston, or cylinder Air filter dirty or contaminated Low Compression Cylinder head gasket leak Cylinder or piston worn Piston rings worn, leaking, broken, or sticking Backfiring Fouled spark plug or incorrect plug or plug gap Carburetion faulty - lean condition Exhaust system air leaks Ignition system faulty:...
Page 63 CHAPTER 3 FUEL SYSTEM/CARBURETION Fuel System Warnings ......Carburetor Operation ......Float System .
Page 65: Fuel System Warnings
FUEL SYSTEM/CARBURETION FUEL SYSTEM WARNING Gasoline is extremely flammable and explosive under certain conditions. Always stop the engine and refuel outdoors or in a well ventilated area. Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Page 66: Carburetor Operation
FUEL SYSTEM/CARBURETION CARBURETOR OPERATION The function of a carburetor is to produce a com- bustible air/fuel mixture by breaking fuel into tiny particles in the form of vapor, to mix the fuel with air in a proper ratio, and to deliver the mixture to the engine.
Page 67: Pilot Jet / Pilot Air Screw / Air/Fuel Mixture
FUEL SYSTEM/CARBURETION PILOT JET From idling to low speeds, the fuel supply is metered by the pilot jet. There are several air bleed openings in the sides of the pilot jet which reduce the fuel to mist. The number stamped on the jet is an indication of the amount of fuel in cc’s which passes through the jet during a one minute inter- Pilot Jet val under a given set of conditions.
Page 68: Jet Needle / Needle Jet / Throttle Opening
FUEL SYSTEM/CARBURETION JET NEEDLE The jet needle has five adjustment grooves cut into the up- Jet Needle per portion, and is tapered from approximately the middle of the needle to the lower end. The top is fixed to the center of the throttle valve by the needle clip, and the tapered end Leaner extends into the needle jet.
Page 69 FUEL SYSTEM/CARBURETION THROTTLE VALVE Throttle Valve The throttle valve controls the rate of engine air intake by moving up and down inside the main bore. At small throttle openings, air flow control is performed chiefly Engine Side Air Box Side by the cutaway.
Page 70: Pilot System
FUEL SYSTEM/CARBURETION PILOT SYSTEM (0-3/8 THROTTLE) The pilot system’s main function is to meter fuel at idle and low speed driving. Though its main function is to supply fuel at low speed, it does feed fuel continuously throughout the entire operating range. Fuel for the pilot jet is drawn from the float bowl, mixed with air regulated by the air screw, and delivered to the engine through the pilot outlet.
Page 71: Slide Cutaway / 1/8-3/8 Throttle
FUEL SYSTEM/CARBURETION SLIDE CUTAWAY (1/8-3/8 THROTTLE) Throttle valve cutaway effect is most noticeable at 1/4 throttle opening. The amount of cutaway is pre-determined for a given engine to maintain a 14:1 air/fuel ratio at part throttle. A steep angle would indicate a fairly lean mixture because there is less resistance to air flow.
Page 72: Jet Needle/Needle Jet (3/8-3/4 Throttle)
FUEL SYSTEM/CARBURETION JET NEEDLE/NEEDLE JET (3/8-3/4 THROTTLE) The jet needle and needle jet have the most effect between 3/8 and 3/4 throttle opening. Some mixture adjust- ment can be accomplished by changing the location of the “E” clip on the needle. Moving the clip down raises the needle in the jet passage and richens the mixture.
Page 73: Main System / 3/4 To Full Throttle
FUEL SYSTEM/CARBURETION MAIN SYSTEM (3/4 TO FULL THROTTLE) The main system is designed for delivering fuel between low speed and high speed operation. This system is made up of the jet needle, needle jet, and main jet. The main system begins to take effect as soon as there is enough air flow into the carburetor venturi to draw fuel up through the main jet and needle jet assembly.
Page 74: Fuel Delivery
FUEL SYSTEM/CARBURETION FUEL DELIVERY (2 CYCLE) The throttle opening chart below demonstrates component relationship to fuel flow versus throttle valve opening. The pilot system’s main function is that of a low speed jet. Its most effective range of fuel delivery is from idle to approximately 3/8 throttle valve opening.
Page 75: Needle And Seat Leakage Test
FUEL SYSTEM/CARBURETION VENT SYSTEMS The fuel tank and carburetor float bowl vent lines supply atmospheric pressure to the fuel in the tank and float bowl. The lines must be free of kinks and restrictions to prevent lean mixture and possible engine damage. Vent lines must be properly routed to prevent damage to the line and to prevent contaminants from entering the carbu- retor or fuel tank.
Page 76: 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 ex- tended periods of storage. NOTE: A drain plug is located on the side of the float bowl. 1.
Page 77: Carburetor Exploded View
FUEL SYSTEM/CARBURETION Carburetor Exploded View 1. Carburetor Assembly 2. Gasket 3. Throttle Spring 4. Bolt 5. Washer Jet Needle “E” 6. Valve, Throttle Clip Position 7. Jet Needle 8. Needle Jet 9. Seal, Float Chamber 10. Main Jet 11. Overflow Tube 12.
Page 78: Troubleshooting
FUEL SYSTEM/CARBURETION TROUBLESHOOTING FUEL STARVATION/LEAN MIXTURE Symptoms: Hard start or no start, bog, backfire, popping through intake / exhaust, hesitation, detonation, low power, spark plug erosion, engine runs hot, surging, high idle, idle speed erratic. No fuel in tank Restricted tank vent, or routed improperly Fuel lines or fuel valve restricted Fuel filter plugged Carburetor vent line(s) restricted...
Page 79 FUEL SYSTEM/CARBURETION TROUBLESHOOTING IDLE TOO LOW Choke cable incorrectly adjusted Idle speed set incorrectly Idle mixture screw misadjusted or damaged Belt dragging Ignition timing incorrect Worn jet needle/needle jet ERRATIC IDLE Choke cable bending or incorrectly adjusted Throttle cable incorrectly adjusted Air leaks, dirty carburetor passages (pilot circuit) Pilot mixture screw damaged or adjusted incorrectly Tight valves...
Page 81 CHAPTER 4 BODY AND STEERING Torque Specifications and Special Tools ... . Frame Photos ........Engine Mounting .
Page 83 BODY / STEERING / SUSPENSION TORQUE SPECIFICATIONS Front A-Arm Attaching Bolt ....26-30 ft. lbs. (36-40 Nm) Handlebar Adjuster Block ....84 in.
Page 84: Frame Photos
BODY / STEERING / SUSPENSION FRAME PHOTOS Side View Rear View Front View...
Page 85: Engine Mounting
BODY / STEERING / SUSPENSION ENGINE MOUNTING Engine Bracket Rubber Bushings Rubber Bushing Mount Tube...
Page 86 BODY / STEERING / SUSPENSION ENGINE MOUNTING 1. Install rubber dampers under footrest and install footrest on frame body. 2. Tighten footrest bolts. 3. There are three (3) engine mounting positions on the frame. Check each bushing of the engine brackets for damage or wear before mounting the engine to the frame body.
Page 87: Shocks And Springs
BODY / STEERING / SUSPENSION SHOCKS AND SPRINGS Rear Shock and Spring Front Shocks and Springs 1. The front shocks and springs are mounted on the frame and A-arm. The front springs on the Sportsman 90 can be adjusted for more or less spring preload depending on rider preference.
Page 88: Suspension A-Arms
BODY / STEERING / SUSPENSION SUSPENSION A-ARMS Right A-arm Upper Spindle Bushing Grease Fitting Grease Fitting Lower Spindle Bushing Bushings Left Spindle Left A-arm Right Spindle 1. Mount the A-arms to the frame body. The A-arm marked “R” is for right side, and A-arm marked “L” is for left side.
Page 89: Steering
BODY / STEERING / SUSPENSION STEERING Steering Post Bushings Steering Post Steering Post Sleeve Right Tie Rod Asm. Left Tie Rod Asm. Seal Circlip Bearing Seal Spacer Washer 1. Grease the steering post sleeve and insert in place. Mount the steering post clamps on post. Install the steering post and tighten the steering post mount nuts to specification.
Page 90 BODY / STEERING / SUSPENSION STEERING, CONT. 2. Install oil seals, bearing, steering nut and associated hardware on the bottom of the steering post. Torque nut to specification. Steering Post Nut Torque: 62-65 ft.lbs. (86-90 Nm) NOTE:Turn the steering post after mounting to make sure the post turns freely in both directions without Steering Post Nut binding.
Page 91: Front Brake
BODY / STEERING / SUSPENSION FRONT BRAKE Brake Cable Brake Shoes Brake Shoes Brake Cam Shaft Return Spring Retainer Spring Retainer Right Brake Plate Spring Left Brake Plate Right Brake Arm Left Brake Arm 1. Front brake backing plate assembly components. Brake Plate Brake Arm Return Spring...
Page 92: Rear Brake And Axle
BODY / STEERING / SUSPENSION FRONT BRAKE, CONT. 3. Mount the front brake assembly on the spindle. 4. Mount the brake drum on the backing plate assembly and tighten the spindle nut to specification. Spindle Nut Torque: 42-45 ft.lbs. (58-62 Nm) 5.
Page 93 BODY / STEERING / SUSPENSION REAR BRAKE AND AXLE, CONT. 1. Apply grease to the swing arm spacer tube. The swing arm assembly must be mounted first. NOTE:The swing arm assembly includes chain protec- tor. 2. Install the swing arm to the frame and tighten the mounting bolt to specification.
Page 94 BODY / STEERING / SUSPENSION REAR BRAKE AND AXLE, CONT. 5. Install rear axle. Tighten the bolts until snug. The rear axle bearing carrier needs to be adjusted for chain tension. Do not tighten to specified torque at this time. 6.
Page 95 BODY / STEERING / SUSPENSION REAR BRAKE AND AXLE, CONT. 9. Install rear brake cable on brake arm. 10. Install chain on drive sprocket and tighten sprocket bolts to specification. Sprocket Bolt Torque: 18 ft.lbs. (25 Nm) 11. Set the chain tension to specification by loosening the lock nuts on the chain adjuster.
Page 96: Fuel And Oil Tank
BODY / STEERING / SUSPENSION FUEL AND OIL TANK 1. Install fuel tank in the frame and tighten bolts to specification. Make sure the fuel tank pads are in place and in good condition. Fuel Tank Mounting Bolt Torque: 103 in.lbs. (12 Nm) 2.
Page 97: Front And Rear Cab
BODY / STEERING / SUSPENSION FRONT AND REAR CAB 1. Install the bumper to the frame and tighten mounting bolts to specification. Front Bumper Mounting Bolt Torque: 103 in.lbs. (12 Nm) 2. There are three (3) mounting positions for the front and rear cab to the frame.
Page 98: Handlebar
BODY / STEERING / SUSPENSION HANDLEBAR Handlebar Grip Left Hand Control Handlebar Right Hand Control Top Handlebar Clamp Bottom Handlebar Clamp Brake Lever Throttle Cable 1. The handlebar assembly includes the right and left side brake levers and the left side control switch.
Page 99 BODY / STEERING / SUSPENSION HANDLEBAR, CONT. 3. Mount the handlebar on the steering post and tighten the clamp bolts to specification. Handlebar Mounting Clamp Bolt Torque: 84 in.lbs. (10 Nm) 4. Install the right side and left side front brake cables as shown.
Page 100: Muffler
BODY / STEERING / SUSPENSION HANDLEBAR, CONT. 7. Install the plate and handlebar cover. MUFFLER 1. Connect the muffler to the cylinder and install. Inspect sealing gaskets upon installation. Replace if necessary. 2. Connect the muffler to the mounting bracket on the frame.
Page 101 CHAPTER 5 ELECTRICAL Special Tools ........Electrical Service Notes .
Page 103: Special Tools
ELECTRICAL SPECIAL TOOLS Fluke 73 Multitester or Tektronix DMM 155 PN 2870659 Strobe Timing Light ..... . . PN 2870630 Hydrometer .
Page 104 6. Check specific gravity of each cell with a hydrometer to assure each has a reading of 1.270 or higher. BATTERY TERMINALS/TERMINAL BOLTS Use Polaris corrosion resistant Nyogelt grease (PN 2871329) on battery bolts. See Battery Installation on page 5.3.
Page 105: Battery Inspection/Removal
2. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable. Coat terminals and bolt threads with Polaris Nyogelt grease PN 2871329. 3. Route cables so they are tucked away in front and behind battery.
Page 106: Load Test
Differences of more than .025 between the lowest and highest cell readings indicate a need to replace the battery. OPEN CIRCUIT VOLTAGE State of Conventional YuMicron™ charge Lead-acid Type Polaris PN 2870876 100% Charged 12.60V 12.70V 75% Charged 12.40V 12.50V 1.10 50% Charged 12.10V...
Page 107: Off Season Storage
+5° F 1.100 +18° F 1.050 +27° F 1. Install battery in vehicle with positive terminal toward the front. Coat threads of battery bolt with Polaris corrosion resistant Nyogelt grease. Polaris Nyogelt Grease PN 2871329 WARNING To avoid the possibility of explosion, connect positive (red) cable first and negative (black) cable last.
Page 108 ELECTRICAL ELECTRONIC PARTS 1. There are four (4) main electronic parts in the Scrambler 50 and Sportsman 90. They are: regulator, resistor... Regulator Resistor ...C.D.I. unit, and ignition coil. Ignition Coil C.D.I. Unit Ignition Coil C.D.I. Unit CURRENT DRAW - KEY OFF Connect an ammeter in series with the negative battery cable.
Page 109: Charging System Testing
ELECTRICAL CHARGING SYSTEM TESTING CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. CAUTION: Never use the electric starter with the ammeter connected, or damage to the meter or meter fuse may result. Do not run test for extended period of time. Do not run test with high amperage accessories. The “break even”...
Page 110: Ignition System
ELECTRICAL IGNITION SYSTEM Ignition System Wiring Schematic Green/Yellow Black/ Black/Red Green Yellow Black C.D.I. Main Switch Stator Ignition Coil Spark Plug 1. Ignition coil resistance: 0.2-0.3 Ω. If the resistance reads (∞) replace coil. 2. Measure the resistance between the spark plug cap and coil.
Page 111 ELECTRICAL IGNITION SYSTEM Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight. Also be sure that colors match when wires are connected. Use the following pages as a guide for troubleshooting.
Page 112: Cranking Output Test
ELECTRICAL CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component. A peak reading voltmeter must be used to perform the tests. A variety of peak reading adaptors are commercially available for use with the Fluke ™...
Page 113: 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. It Remove the battery and properly ser- should be 12.4 volts or more. Is it? vice.
Page 114 ELECTRICAL CHARGING SYSTEM “BREAK EVEN” TEST CAUTION: Do not connect or disconnect the battery cable or ammeter with the engine running. CAUTION: Never use the electric starter with the ammeter connected, or damage to the meter or meter fuse may result.
Page 115: Alternator Output Test (Ac Amp)
ELECTRICAL ALTERNATOR OUTPUT TEST (AC AMP) This test measures AC amperage from the alternator. SMaximum alternator output will be indicated on the meter. It is not necessary to increase engine RPM above idle. SPlace the red lead on the tester in the 10A jack. STurn the selector dial to the AC amps (A) position.
Page 116: Voltage Drop Test
ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn SBattery discharged - low specific gravity SLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) SRelated wiring loose, disconnected, or corroded SPoor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) SFaulty starter button SFaulty ignition switch (Do other systems function?)
Page 117: Starter System
ELECTRICAL STARTER SYSTEM 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 118: Starter Motor Disassembly
ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE: Use electrical contact cleaner to clean starter motor parts. Some solvents may leave a residue or damage inter- nal parts and insulation. 1. Note the alignment marks on both ends of the starter motor casing. These marks must align during reassembly.
Page 119: Brush Inspection/Replacement
ELECTRICAL STARTER MOTOR DISASSEMBLY, CONT. 4. Remove shims from armature shaft. NOTE: All shims must be replaced during reassembly. BRUSH INSPECTION/REPLACEMENT 1. Using a digital multitester, measure the resistance between the cable terminal and the insulated brush. The reading should be .3 ohms or less. Measure the resistance between the cable terminal and brush housing.
Page 120: Armature Testing
ELECTRICAL BRUSH INSPECTION/REPLACEMENT, CONT. 6. Place a wrap of electrical tape on the threads of the terminal bolt to prevent O-Ring damage during reinstallation. 7. Install the O-Ring over the bolt. Make sure the O-ring is fully seated. 8. Remove the electrical tape and reinstall the two small phenolic washers, the large phenolic washer, flat washer, and nut.
Page 121: Starter Assembly
ELECTRICAL STARTER ASSEMBLY 1. Place armature in field magnet casing. 2. Place shims on drive end of armature shaft with phenolic washer outermost on shaft. Engage tabs of stationary washer in drive end housing, holding it in place with a light film of grease. 3.
Page 122: Electronic Throttle Control (Etc)
ELECTRICAL ELECTRONIC THROTTLE CONTROL (ETC) The Electronic Throttle Control (ETC) system is designed to limit the engine RPM of an ATV in the event of a mechanical problem with the throttle mechanism. The ETC switch is mounted independently of the throttle actua- tor lever inside the throttle block assembly.
Page 123: Ignition System Troubleshooting
ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark, Weak or Intermittent Spark SSpark plug gap incorrect SFouled spark plug SFaulty spark plug cap or poor connection to high tension lead SRelated wiring loose, disconnected, shorted, or corroded SEngine Stop switch or ignition switch faulty SETC switch misadjusted or faulty STerminal board or connections wet, corroded SPoor ignition coil ground (e.g.
Page 124 ELECTRICAL WIRING DIAGRAM, 2001 SCRAMBLER 50 5.22...
Page 125 ELECTRICAL WIRING DIAGRAM 2001 SCRAMBLER 90, SPORTSMAN 90 5.23...

This manual is also suitable for:

2001 scrambler 2001 90 sportsman 90

Polaris 2001 50 SCRAMBLER Manual

Chapter 1 General Information

Chapter 2 Engine

Chapter 3 Fuel System/Carburetion

Chapter 4 Body and Steering

Chapter 5 Electrical

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Troubleshooting

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Summary of Contents for Polaris 2001 50 SCRAMBLER

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