Home ▸ Polaris ▸ 2003 Polaris ATV Scrambler 50 – Predator 90 – Scrambler 90 – Sportsman 90 DIY Service – Repair – Maintenance Manual – 89946338

2003 Polaris ATV Scrambler 50 – Predator 90 – Scrambler 90 – Sportsman 90 DIY Service – Repair – Maintenance Manual – 89946338

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#❶ 2003 Scrambler 50 / Predator 90 / Scrambler 90 / Sportsman 90 * DIY (DO-IT-YOURSELF) Factory Service / Repair / Maintenance Manual – Download !!

( VERY HIGH QUALITY FACTORY SERVICE MANUAL – 47+ MB !! )

1. Requirements: Adobe PDF Reader

2. Language: English

3. File Format: PDF

4. Compatible: All Versions of Windows & Mac

5. Downloadable:YES

Description:

COVERS ALL MODELS & ALL REPAIRS A-Z

THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE.

COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE!

YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE CD-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN.

ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES!

FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE.

ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC!

SERVICE MANUAL COVERS:

Table of Contents

Chapter 1 General Information Maintenance

Chapter 2 Engine / Transmission / CVT

Chapter 3 Carburetion

Chapter 4 Body / Steering suspension

Chapter 5 Electrical

A–arm Mounting Bolt Torque, 4.4

Air Cleaner, 1.18

Air Screw, 3.6

Air Screw Adjustment, 1.13

Air Screw Adjustment Specifications, 1.13

Air/Fuel Mixture Ratio, 3.6

Alternator Output Test, 5.9

Axle Nut Torque, 4.8

Battery Charging, 5.6

Battery Charging Chart, 5.7

Battery Inspection/Removal, 5.5

Battery Installation, 5.5

Battery Load Test, 5.5

Battery Off Season Storage, 5.6

Battery Service, 5.4

Battery Terminals/Bolts, 5.4

Battery Testing, 5.5

Bearing Carrier Bolt Torque, 4.9

Bearing Housing Bolt Torque, 1.11

Belt Inspection, 2.16

Brake Lever Free Play, Front, 1.10, 4.12, 4.14

Brake Lever Free Play, Rear, 1.10, 4.12, 4.14

Brake Lever Travel, Front, 1.10, 4.12, 4.14

Brake Lever Travel, Rear, 1.10, 4.12, 4.14

Brake Light Bulb Replacement, 5.3

Cab Mounting Bolt Torque, 4.10, 4.11

Camber & Caster, 1.20

Carburetor Component Functions, 3.9

Carburetor Float Bowl Draining, 1.17, 3.11

Carburetor Float Height, 3.10

Carburetor Float Height Specification, 3.10

Carburetor Main System, 3.9

Carburetor Needle and Seat Testing, 3.10

Carburetor Operation, 3.4

Carburetor Specifications, 3.4

Carburetor System Function, 3.3

Carburetor Venting Systems, 3.10

Chain Adjuster Lock Nut Torque, 1.11

Chain Adjustment, 1.10

Chain Tension Spec, 1.10

Chain Tension Specification, 4.9

Chain Tensioner Nut Torque, 4.9

Charging System Break Even Test, 5.9

Charging System Testing, 5.8

Choke Adjustment, 1.14

Clutch Brake Lining Service Limit, 2.16

Clutch Cover Inner Diameter Service Limit, 2.16

Clutch Cover Inspection, 2.16

Coil and Enrichment Valve Tests, 5.16

Cold Weather Starting Procedures, 3.12

Compression Spring Inspection, 2.16

Compression Spring Service Limit, 2.16

Compression Test, 1.18

Connecting Rod Inspection, 2.13

Connecting Rod Small End Service Limit, 2.14

Conversion Table, 1.6

Crankcase Assembly, 2.18

Crankcase Bolt Torque, 2.18

Crankcase Cover Bolt Torque, 2.21

Crankcase Separating Tool, 2.9

Crankcase Separation, 2.9

Cranking and ETC Tests, 5.15

Crankshaft Alignment Fixture, 2.14

Crankshaft Removal Tool, 2.9

Crankshaft Runout, 2.14

Current Draw, 5.9

Cylinder Cleaning, 2.13

Cylinder Compression Specification, 1.18

Cylinder Head Inspection, 2.11

Cylinder Head Nut Torque, 2.21

Cylinder Head Warp, 2.11

Cylinder Honing, 2.12

Cylinder Inspection, 2.11

Cylinder Warp, 2.11

Decimal Equivalents, 1.7

Drive Belt Width Service Limit, 2.16

Drive Clutch Nut Torque, 2.17

Driven Clutch Nut Torque, 2.17

Driveshaft (Transmission) Assembly, 2.11

Electrical Service Notes, 5.2

Electronic Speed Control System, 1.9, 5.2

Engine Assembly, 2.18

Engine Disassembly, 2.4

Engine Inspection, 2.11

Engine Installation Notes, 2.4

Engine Mounting, 4.2, 4.3

Engine Removal, 2.3

Engine Torque Specifications, 2.2

ETC Switch Testing, 5.14

Fan Bolt Torque, 2.21

Float System, Carburetor, 3.5

Flywheel Nut Torque, 2.20

Flywheel Puller Tool, 2.6

Frame Photos, 4.2

Frame, Nuts, Bolts, Fasteners, 1.20

Front and Rear Cab, Scrambler, 4.10

Front and Rear Cab, Sportsman, 4.10

Front Brake Inspection, 1.10

Front Brake System, 4.6

Front Bumper Mounting Bolt Torque, 4.10, 4.11

Front Shock and Spring Inspection, 1.11

Fuel and Oil Tank, 4.9

Fuel Filter Maintenance, 1.16

Fuel Line Maintenance, 1.16

Fuel System Warnings, 1.16

Fuel Tank Mounting Bolt Torque, 4.9

Glossary of Terms, 1.8

Grease Fitting Lubrication, 1.11

Handlebar Asm., Scrambler, 4.13

Handlebar Asm., Sportsman, 4.11

Handlebar Mounting Clamp Bolt Torque, 4.12,

4.14

Honing to Oversize, 2.13

Idle Speed Adjustment, 1.13

Idle Speed Specification, 1.13

Idler Gear Bolt Torque, 2.17

Inspection Schedule, 1.4

Intake Manifold Bolt Torque, 2.20

Jet Needle, 3.6

Jet Needle/Needle Jet Effects, 3.8

Jetting Guidelines, 3.3

Kick Start and Spring Installation, 2.23

Lubricants, 1.5

Main Jet, 3.7

Model Identification, 1.2

Motor Mount Bolt Torque, 4.3

Muffler, 4.15

Muffler Mounting Bolt Torque, 4.15

Needle Jet, 3.6

New for 2002 Models, 1.9, 5.2

Oil Pump Adjustment, 1.15

Oil Pump Bolt Torque, 2.19

Oil Pump Drive Gear Removal Tool, 2.7

Oil Pump Installation, 2.18

Oil Pump Troubleshooting, 1.16

Oil Tank Mounting Bolt Torque, 4.9

Paint Codes, 1.4

Pilot Jet, 3.5

Pilot System, 3.8

Piston Inspection, 2.12

Piston Installation, 2.20

Piston Pin Hole Inspection, 2.12

Piston Pin Hole Service Limit, 2.12

Piston Pin Inspection, 2.13

Piston Pin Service Limit, 2.13

Piston Ring Installed Gap, 2.12

Piston to Cylinder Clearance, 2.12

Pod Mounting Screw Torque, 4.13

Publication Numbers, 1.4

PVT System Assembly, 2.15

Rear Brake and Axle, Exploded View, 4.7

Rear Brake Inspection, 1.10

Rear Shock and Spring Inspection, 1.11

Rear Shock Mounting Bolt Torque, 4.7

Reed Valve Air Gap Service Limit, 2.14

Reed Valve Inspection, 2.14

Serial Number Locations, 1.2

Shock Mounting Bolt Torque, 4.4

Shocks and Springs, Exploded View, 4.4

Slide Cutaway, 3.8

Spark Plug Recommendation, 5.10

Special Tools, 3.3

Special Tools, Electrical, 5.2

Special Tools, Engine, 2.2

Special Tools, Suspension, 1.5, 4.3

Specifications, General, 1.3

Specifications, Torque, Standard, 1.5

Specifications, Torque, Steering, 4.3

Speed Control Systems, 1.9, 5.2, 5.3

Spindle Nut Torque, 4.5, 4.7

Sprocket Bolt Torque, 4.8

Starter Armature Testing, 5.13

Starter Assembly, 5.13

Starter Brush Inspection/Replacement, 5.12

Starter Disassembly, 5.12

Starter System Test, 5.11

Starter Wheel Installation, 2.21

Stator Installation, 2.19

Stator Mounting Bolt Torque, 2.19

Stator Trigger/Flywheel Gap, 2.19

Steering Maintenance, 1.20

Steering Nut Torque, 4.6

Steering Post Nut Torque, 4.5

Steering System, 4.5

Suspension A–arms, Exploded View, 4.4

Swing Arm Mounting Bolt Torque, 4.7

Tap Drill Chart, 1.7

Throttle Cable Adjustment, 1.14

Throttle Opening vs. Fuel Flow, 3.7

Throttle Operation, 1.13

Throttle Stop Speed Control System, 1.9, 5.3

Throttle Valve, 3.7

Tie Rod Bolt Torque, 4.6

Tie Rod Jam Nut Torque, 4.6

Tire Inspection, 1.19

Tire Pressure, 1.19

Tire Tread Depth, 1.19

Toe Alignment, 1.21

Toe Alignment Adjustment, 1.21

Transmission Cover Bolt Torque, 2.11

Transmission Fluid Specifications, 1.12

Transmission Lubrication, 1.12

Troubleshooting, Engine, 2.25

Troubleshooting, Fuel System/Carb, 3.13

Troubleshooting, Ignition System, 5.16

Troubleshooting, Spark Plug, 2.25

Troubleshooting, Starter System, 5.10

Vechicle Inspection, 1.10

Vent Line Maintenance, 1.16

Voltage Drop Test, 5.10

Voltage Test Open Circuit, 5.5

VIN Identification, 1.2

Wheel, Hub, and Spindle Torque Table, 1.18

Wheel Inspection, 1.18

Wheel Installation, 1.19

Wheel Nut Inspection, 1.12

Wheel Nut Torque, 1.12

Wheel Removal, 1.18

Wiring Diagram, Quick Reference, 5.17

Wiring Diagram, Scrambler 50, 5.18

Wiring Diagram, Scrambler 90/Sportsman

90/Predator 90, 5.19

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