Polaris 2003 Predator 90, Service Manual

Page 1: ...SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 SERVICE MANUAL PN 9918068 The Way Out...

Page 2: ...rations 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...

Page 3: ...on 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...

Page 4: ...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...

Page 5: ...sure 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 T...

Page 6: ...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 NUMB...

Page 7: ...GENERAL INFORMATION 1 3 2003 YOUTH MODEL ATVS SCRAMBLER 50 SCRAMBLER 90 SPORTSMAN 90 PREDATOR 90 NOTE Colors will vary upon model...

Page 8: ...GENERAL INFORMATION 1 4...

Page 9: ...atic 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 w...

Page 10: ...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 Gl...

Page 11: ...k 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 P...

Page 12: ...ers 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 q...

Page 13: ...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...

Page 14: ...the end of a lever one meter in length applied in a rotational direction l or ltr Liter Left Side Always referred to based on normal operating position of the driver m Meter meters Mag Magneto Magnet...

Page 15: ...speed of the ATV Speed can be adjusted by removing or installing the jumper on the CDI A With the jumper installed 50cc models will travel no faster than 10 mph and 90cc models will travel no faster t...

Page 16: ...0 mm Front Brake Lever Travel 50 cc 1 1 8I 28 mm 90 cc 1 3 4 45 mm REAR BRAKE 3 The rear brake is operated using the left hand brake lever To adjust the rear brake setting turn the rear brake adjuster...

Page 17: ...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 SHOCK...

Page 18: ...icant 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...

Page 19: ...ion 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...