Polaris 50 SCRAMBLER (2001) User guide

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

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 &

Year Designation

Basic Chassis
Designation

Model Option

Engine Designation

VIN IDENTIFICATION

World Mfg. ID

Vehicle Descriptor

Vehicle Identifier

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4XAEA

Body Style

Powertrain

05A* 1P0 00 0 00

Emissions

Engine

Check Digit

Model
Year

Plant No.

Individual Serial No.

* 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).

A

Front

B

1.1

GENERAL INFORMATION

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

CARBURETOR Mikuni AM3 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

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)

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)*

6.5 ft.lbs (8.82 Nm) @ 6000
RPM

Mikuni AM7 with automatic

choke

Single Shock/Swing Arm

with 2″ (5 cm) Travel

56.1x34x36.1″

(142.4x86.3x91.8 cm)

6.5 ft.lbs (8.82 Nm) @ 6000
RPM

Mikuni AM7 with automatic

choke

Single Shock/Swing Arm

with 2″ (5 cm) Travel

57.6x34.4x36.6″

(146.3x87.4x93 cm)

* Check owner’s manual for loading requirements and restrictions.

1.2

PUBLICATION NUMBERS

GENERAL INFORMATION

Year Model Model No. Owner’s

Manual PN

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.

Parts

Manual PN

Parts

Micro Fiche

PN

Service
Manual

PAINT CODES

PAINTED PART COLOR

DESCRIPTION

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.

DITZLER
NUMBER

POLARIS

NUMBER

1.3

GENERAL INFORMATION

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

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

TORQUE (ft.lbs. / in.lbs.) TORQUE (Nm)

POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD­UCT 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..

1.4

TORQUE CONVERSIONS

Newton Meter to Pound Foot and Pound Inch

GENERAL INFORMATION

1.5

GENERAL INFORMATION

TORQUE CONVERSIONS

Newton Meter to Pound Foot and Pound Inch

1.6

DECIMAL EQUIVALENTS

1/64 .0156. . . . . . . . . . . . . . . . . . . . . . . . .

1/32 .0312 1 mm = .0394″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/64 .0469. . . . . . . . . . . . . . . . . . . . . . . . .

5/64 .0781 2 mm = .0787″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7/64 .1094 3 mm = .1181″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9/64 .1406. . . . . . . . . . . . . . . . . . . . . . . . .

11/64 .1719. . . . . . . . . . . . . . . . . . . . . . . .

13/64 .2031. . . . . . . . . . . . . . . . . . . . . . .

15/64 .2344 6 mm = .2362″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17/64 .2656 7 mm = .2756″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19/64 .2969. . . . . . . . . . . . . . . . . . . . . . .

21/64 .3281. . . . . . . . . . . . . . . . . . . . . . .

23/64 .3594. . . . . . . . . . . . . . . . . . . . . . .

25/64 .3906 10 mm = .3937″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27/64 .4219 11 mm = .4331″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29/64 .4531. . . . . . . . . . . . . . . . . . . . . . .

31/64 .4844. . . . . . . . . . . . . . . . . . . . . . .

33/64 .5156. . . . . . . . . . . . . . . . . . . . . . .

35/64 .5469 14 mm = .5512″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37/64 .5781 15 mm = .5906″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39/64 .6094. . . . . . . . . . . . . . . . . . . . . . .

41/64 .6406. . . . . . . . . . . . . . . . . . . . . . .

43/64 .6719

45/64 .7031 18 mm = .7087″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47/64 .7344 19 mm = .7480″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49/64 .7656. . . . . . . . . . . . . . . . . . . . . . .

51/64 .7969. . . . . . . . . . . . . . . . . . . . . . .

53/64 .8281. . . . . . . . . . . . . . . . . . . . . . .

55/64 .8594 22 mm = .8661″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57/64 .8906 23 mm = .9055″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59/64 .9219. . . . . . . . . . . . . . . . . . . . . . .

61/64 .9531. . . . . . . . . . . . . . . . . . . . . . .

63/64 .9844. . . . . . . . . . . . . . . . . . . . . . .

1/16 .0625. . . . . . . . . . . . . .

3/32 .0938. . . . . . . . . . . . . . . . . . .

1/8 . .1250. . . . . . . .

5/32 .1563 4 mm = .1575″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/16 .1875 5 mm = .1969″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7/32 .2188. . . . . . . . . . . . . . . . . . .

1/4 .25. . . . . . . . . .

9/32 .2813. . . . . . . . . . . . . . . . . . .

5/16 .3125 8 mm = .3150″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11/32 .3438 9 mm = .3543″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3/8 .375. . . . . . . . . .

13/32 .4063. . . . . . . . . . . . . . . . . .

7/16 .4375. . . . . . . . . . . . . .

15/32 .4688 12 mm = .4724″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1/2 .5 13 mm = .5118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17/32 .5313. . . . . . . . . . . . . . . . . .

9/16 .5625. . . . . . . . . . . . . .

19/32 .5938. . . . . . . . . . . . . . . . . .

5/8 .625 16 mm = .6299″. . . . . . . . . . . . . . . . . . . . . . . . . . .

21/32 .6563 17 mm = .6693″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

11/16 .6875. . . . . . . . . . . . .

23/32 .7188. . . . . . . . . . . . . . . . . .

3/4 .75. . . . . . . . . .

25/32 .7813 20 mm = .7874″. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13/16 .8125 21 mm = .8268″. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27/32 .8438. . . . . . . . . . . . . . . . . .

7/8 .875. . . . . . . . . .

29/32 .9063. . . . . . . . . . . . . . . . . .

15/16 .9375 24 mm = .9449″. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31/32 .9688 25 mm = .9843. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1.0. . . . . . . . . . .

GENERAL INFORMATION

1.7

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

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

1.8

GENERAL INFORMATION

SAE TAP DRILL SIZES

Thread Size Drill Size Thread Size Drill Size

#0-80 3/64
#1-64 53
#1-72 53
#2-56 51
#2-64 50
#3-48 5/64
#3-56 45
#4-40 43
#4-48 42
#5-40 38
#5-44 37
#6-32 36
#6-40 33
#8-32 29
#8-36 29
#10-24 24
#10-32 21
#12-24 17
#12-28 4.6mm
1/4-20 7
1/4-28 3
5/16-18 F
5/16-24 I
3/8-16 O
3/8-24 Q
7/16-14 U
7/16-20 25/64

1/2-13 27/64
1/2-20 29/64
9/16-12 31/64
9/16-18 33/64
5/8-11 17/32
5/8-18 37/64
3/4-10 21/32
3/4-16 11/16
7/8-9 49/64
7/8-14 13/16
1-8 7/8
1-12 59/64
1 1/8-7 63/64
1 1/8-12 1 3/64
1 1/4-7 1 7/64
1 1/4-12 1 11/64
1 1/2-6 1 11/32
1 1/2-12 1 27/64
1 3/4-5 1 9/16
1 3/4-12 1 43/64
2-4 1/2 1 25/32
2-12 1 59/64
2 1/4-4 1/2 2 1/32
2 1/2-4 2 1/4
2 3/4-4 2 1/2
3-4 2 3/4

METRIC TAP DRILL SIZES

Tap Size Drill Size Decimal Equivalent Nearest Fraction

3 x .50
3 x .60
4 x .70
4 x .75
5 x .80
5 x .90
6 x 1.00
7 x 1.00
8 x 1.00
8 x 1.25
9 x 1.00
9 x 1.25
10 x 1.25
10 x 1.50
11 x 1.50
12 x 1.50
12 x 1.75

#39
3/32
#30
1/8
#19
#20
#9
16/64
J
17/64
5/16
5/16
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
11/32
3/8
13/32
13/32

1.9

GENERAL INFORMATION

GLOSSARY OF TERMS

ABDC: After bottom dead center.
ACV: Alternating current voltage.
Alternator: Electrical generator producing voltage alternating current.
ATDC: After top dead center.
BBDC: Before bottom dead center.
BDC: Bottom dead center.
BTDC: Before top dead center.
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.
Clutch Buttons: Plastic bushings which transmit rotation of the clutch to the movable sheave in the drive and driven

clutch.
Clutch Offset: Drive and driven clutches are offset so that drive belt will stay nearly straight as it moves along the clutch

face.
Clutch Weights: Three levers in the drive clutch which relative to their weight, profile and engine RPM cause the drive

clutch to operate.

Condenser/Capacitor: A storage reservoir for DC voltage.
Crankshaft Run-Out: Run-out or “bend” of crankshaft measured with a dial indicator while crankshaft is supported

between centers on V blocks or resting in crankcase. Measure at various points especially at PTO.

DCV: Direct current voltage.
Dial Bore Gauge: A cylinder measuring instrument which uses a dial indicator. Good for showing taper and

out-of-round in the cylinder bore.

Electrical Open: Open circuit. An electrical circuit which isn’t complete.
Electrical Short: Short circuit. An electrical circuit which is completed before the current reaches the intended load.

(i.e. a bare wire touching the chassis).

End Seals: Rubber seals at each end of the crankshaft.
Engagement RPM: Engine RPM at which the drive clutch engages to make contact with the drive belt.
ft.: Foot/feet.
Foot Pound: Ft. lb. A force of one pound at the end of a lever one foot in length, applied in a rotational direction.
g: Gram. Unit of weight in the metric system.
gal.: Gallon.
HP: Horsepower.
ID: Inside diameter.
in.: Inch/inches.
Inch Pound: In. lb. 12 in. lbs. = 1 ft. lb.

2

kg/cm
kg-m: Kilogram meters.
Kilogram/meter: A force of one kilogram at the end of a lever one meter in length, applied in a rotational direction.
l or ltr: Liter.

: Kilograms per square centimeter.

lbs/in2: Pounds per square inch.
Left Side: Always referred to based on normal operating position of the driver.

1.10

GENERAL INFORMATION

GLOSSARY OF TERMS

m: Meter/meters.
Mag: Magneto.
Magnetic Induction: As a conductor (coil) is moved through a magnetic field, a voltage will be generated in the

windings. Mechanical energy is converted to electrical energy in the stator.

mi.: Mile/miles.
mm: Millimeter. Unit of length in the metric system. 1mm = approximately .040″.
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current flow.
oz.: Ounce/ounces.
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.

Reservoir Tank: The fill tank in the liquid cooling system.
Resistance: In the mechanical sense, friction or load. In the electrical sense, ohms. Both result in energy conversion to

heat.

Right Side: Always referred to based on normal operating position of the driver.
RPM: Revolutions per minute.
Secondary Clutch: Driven clutch on chaincase or jackshaft.
Seized Piston: Galling of the sides of a piston. Usually there is a transfer of aluminum from the piston onto the cylinder

wall. Possible causes: 1) improper lubrication; 2) excessive temperatures; 3) insufficient piston clearance; 4) stuck
piston rings.

Stator Plate: The plate mounted under the flywheel supporting the battery charging coils.
TDC: Top dead center. Piston’s most outward travel from crankshaft.
Volt: The unit of measure for electrical pressure of electromotive force. Measured by a voltmeter in parallel with the

circuit.

Watt: Unit of electrical power. Watts = amperes x volts.
WOT: Wide open throttle.

1.11

GENERAL INFORMATION

INSPECTION SCHEDULE

Service Item Initial Service

(After two weeks)

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.

Monthly Every 6 Months Yearly

1.12

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.

GENERAL INFORMATION

Front Brake Lever Free Play:

.40-.80I (10-20 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 nut until brake is set to specification.

Rear Brake Lever Free Play:

.40-.80I (10-20 mm)

Rear Brake Lever Travel:

50 cc= 1 1/8I (28 mm)
90 cc = 2 1/2″ (65 mm)

1.13

GENERAL INFORMATION

VEHICLE INSPECTION

Chain Adjustment

1. Remove the rear cover and loosen the four bearing
housing bolts.

2. Loosen the chain adjuster lock nut. Turn the chain
adjuster clockwise until chain is set to specification.
Tighten the chain adjuster lock nut to specification.

Chain Tension Specification:

3/8-3/4″ (10-20 mm) Deflection

Chain Adjuster Lock Nut Torque:

84 in.lbs (9.4 Nm)

3. Tighten the four bearing housing bolts to
specification. Re-install rear cover.

Bearing Housing Bolt Torque:

43 ft.lbs (60 Nm)

Lubrication

4. Lubricate grease fittings on spindles monthly with
Polaris All Season Grease, or more frequently if
used often.

Bolts

Polaris Premium All Season Grease
14 oz. PN 2871423

Grease Gun Kit PN 2871312

1.14

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.

Rear Shock and Spring

2. Inspect the rear shock and spring to ensure proper
function. If the shock is leaking oil, replace. Inspect
the swing arm and weldments for any sign of
damage.

GENERAL INFORMATION

Wheel Nuts

3. Inspect the front and rear wheel nuts for tightness.
Re-torque wheel nuts monthly to specification.

Wheel Nut Torque:

22-29 ft.lbs (30-40 Nm)

1.15

GENERAL INFORMATION

TRANSMISSION LUBRICATION

The transmission lubricant level should be checked and changed in accordance with the maintenance schedule.

Be sure vehicle is level before proceeding.
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:
Operating Range

tip of dipstick.

Drain Plug Torque:

14 ft. lbs. (19.4 Nm)

To check the level:

1. Remove fill plug and wipe clean.

2. Reinstall fill plug completely, remove and check the

level. Add the proper lubricant as required to bring
level into operating range. Operating range is 1/2″
(12.7 mm) below the tip of the dipstick.

To change lubricant:

1. Place a drain pan beneath the transmission oil drain
plug area.

2. Remove the drain plug and wipe the magnetic end
clean to remove accumulated metallic filings.

3. After the oil has drained completely, install a new
sealing washer and install the drain plug. Torque to
14 ft. lbs. (19.3 Nm).

4. Add the proper lubricant through the fill plug hole.
Do not overfill.

5. Check for leaks.

10 fl.oz. / 300 ml. . . . .

: 1/2″ (12.7 mm) below

Fill Plug

Vent Hose

Drain Plug

1.16

THROTTLE OPERATION

Check for smooth throttle opening and closing in all han­dlebar 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.

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 Adjustment:

1.5 Turns Out from Lightly Seated

GENERAL INFORMATION

2. Warm up the engine to operating temperature (about
10 minutes).

3. Set idle speed to 600 RPM.

NOTE: Adjusting the air screw may affect idle speed.
Always check throttle cable freeplay after adjusting idle
speed and adjust if necessary.

4. Turn the screw in (to richen) or out (to lean) the
mixture. Adjust air screw for best throttle response
and smooth idle.

5. Re-adjust idle speed if necessary.

Idle Speed
Screw

Air Screw

1.17

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).

NOTE: Adjusting the idle speed affects throttle cable
freeplay and electronic throttle control (ETC) adjustment.
Always check throttle cable freeplay after adjusting idle
speed and adjust if necessary.

Idle Speed:

600 ± 200 RPM

THROTTLE CABLE / ELECTRONIC THROTTLE
CONTROL (ETC SWITCH) ADJUSTMENT

1. Slide boot off throttle cable adjuster and jam nut.

2. Set parking brake.

3. Start engine and set idle to specified RPM.

NOTE: Be sure the engine is at operating temperature.
See Idle Speed Adjustment.

4. Loosen lock nut on in-line cable adjuster (Ill. 1).

Idle
Screw

Boot

Lock­nut

5. Turn cable adjuster out until engine RPM begins to
increase.

6. Turn cable adjuster back in until throttle lever has
1/16″ (.16 cm) of travel before engine RPM
increases.

NOTE: Be sure ETC switch plunger is held inward by
throttle cable tension (see ill. 2).

7. Tighten lock nut securely and slide boot completely in
place to ensure a water-tight seal.

1.18

Ill. 1

Switch Plunger Must
Be Held In By Cable
Tension

Throttle Cable
Adjuster

Ill. 2

Lock Nut

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 neces­sary.

8. Turn handlebars from left to right through the entire
turning range. If idle speed increases, check for
proper cable routing. If cable is routed properly and
in good condition, repeat adjustment procedure.

Direction
of travel

Ill. 3

Switch Plunger Must
Be Held In By Cable
Tension

1/16″ - 1/8″

Freeplay

Throttle Cable
Adjuster

Ill. 4

Lock Nut

1.19

GENERAL INFORMATION

OIL PUMP ADJUSTMENT PROCEDURE

1. Before adjusting the oil pump, check engine idle
RPM and set to specification. Adjust if necessary.

2. Check and adjust throttle lever free play (ETC
switch).

3. Apply parking brake.

4. Remove fan shroud.

5. Start the engine and let it idle.

CAUTION:

6. Place very slight pressure on the throttle lever until
all freeplay is removed from throttle cable to
carburetor (to the point where the carb slide is just
starting to rise and engine RPM begins to
increase).

7. Expose oil pump adjuster. Loosen lock nut and turn
adjuster in or out until all freeplay is removed from
oil pump cable (the point where the oil pump arm is
just starting to move off of its stop).

NOTE: The pump stop keeps the pump arm from rotat­ing any farther down than the idle position so no visual
alignment of marks is necessary.

Keep away from moving fan.

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
oil to flow from the bleed screw for five to ten
seconds. Tighten bleed screw. CAUTION: Never
run the engine with the bleed screw loose. Loss of
oil will cause serious engine damage.

3. Start the engine and turn the oil pump lever or reel
to its full up (open) position. Allow engine to idle
with the lever in this position for ten to twenty
seconds to make sure all air is out of the system.

Bleed Screw

Direction of Pump Rotation

1.20

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. Test the oil delivery check valve with a low pressure
pump and gauge.

4. Start engine and lift oil pump lever to full open position.

5. Oil should pulse from the delivery line every few seconds.
If it does not, suspect one of the following:

A. Oil line plugged

B. Oil tank vent line restricted

C. Oil line leaking or blocked

D. Faulty oil pump or drive mechanism

E. Air in oil Lines

F. Insufficient/Improper oil in oil tank

1.21

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.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison­ous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine is hot. Severe burns may result.

FUEL LINES

1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.

2. Be sure fuel lines are routed properly and secured with
cable ties. CAUTION: Make sure lines are not kinked
or pinched.

3. Replace all fuel lines every two years.

VENT LINES

1. Check fuel tank, oil tank, carburetor, battery and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.

2. Be sure vent lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are not
kinked or pinched.

FUEL FILTER

The fuel filter should be replaced in accordance with the
Periodic Maintenance Chart or whenever sediment is vis­ible in the filter.

1. Shut off fuel supply at fuel valve.

2. Remove line clamps at both ends of the filter.

3. Remove fuel lines from filter.

4. Install new filter and clamps onto fuel lines.

5. Turn fuel valve ON.

6. Start engine and inspect for leaks.

1.22

CARBURETOR DRAINING

The carburetor float bowl should be drained periodically to
remove moisture or sediment from the bowl, or before ex­tended periods of storage.

NOTE: A drain plug is located on the side of the float bowl.

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain spigot
or bowl drain hose.

3. Loosen drain screw and allow fuel in the float bowl and
fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “on”.

7. Check for fuel leaks.

GENERAL INFORMATION

8. Start engine and re-check for leaks.

RES

OFF

ON

1.23

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. Remove three (3) screws on the airbox. Slide car-

buretor boot clamp off of carburetor.

2. Remove the airbox cover to expose the filter ele-

ment.

3. Carefully wash the element in soapy water and dry

it. Replace filter if necessary.

4. Lightly grease the sealing surfaces of the air filter

cover. Install cover.

5. Install three (3) screws and boot clamp.

1.24

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. Lbs. (30-40 Nm)

Front Spindle Nut 42-45 Ft. Lbs. (58-62 Nm)

Rear Hub Retaining Nut 78-81 Ft. Lbs. (108-112 Nm)

WHEEL REMOVAL FRONT OR REAR

1. Stop the engine and lock the parking brake.

2. Loosen the wheel bolts slightly.

3. Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.

4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLATION

1. With the transmission in gear and the parking brake
locked, place the wheel in the correct position on the
wheel hub. Be sure the valve stem is toward the
outside and rotation arrows on the tire point toward
forward rotation.

2. Attach the wheel nuts and finger tighten them.

3. Lower the vehicle to the ground.

4. Securely tighten the wheel nuts to the proper torque
listed in the table above.

CAUTION:

If wheels are improperly installed it could affect vehicle
handling and tire wear.

Flange Nuts:
Flat side against wheel

1.25

GENERAL INFORMATION

TIRE PRESSURE

Tire Pressure Inspection (PSI - Cold)

Front Rear

2 2

TIRE INSPECTION

CAUTION:

Maintain proper tire pressure. Refer to the tire pressure
warning decal applied to the vehicle.

Improper tire inflation may affect ATV maneuverability.

When replacing a tire always use original equipment size
and type.

The use of non-standard size or type tires may affect ATV
handling.

Tread
Depth 1/8I (3 mm)

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″
(3 mm) or less.

WARNING

Operating an ATV with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.

Worn tires can cause an accident.
Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

FRAME, NUTS, BOLTS, FASTENERS

Periodically inspect the torque of all fasteners in accor­dance with the maintenance schedule. Check that all cot­ter pins are in place. Refer to specific fastener torques
listed in each chapter.

1.26

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.

Rear rim measure­ment should be
1/16″ to 1/8″ (.2 to
.3 cm) more than
front rim measure­ment.

NOTE: The steering post arm (frog) can be used as an indicator of whether the handle­bars are straight. The frog should always point straight back from the steering post.

1.27

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. The frog should always
point straight back from the steering post.

3. Place a chalk mark on the face of the front tires
approximately 10″ (25.4 cm) from the floor as close to
the hub/axle center line as possible. NOTE: It is
important that both marks be equally positioned from
the ground in order to get an accurate measurement.

4. Measure the distance between the marks and record
the measurement. Call this measurement “A”.

5. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with
the hub/axle centerline.

6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle
toe alignment. The recommended vehicle toe tolerance is 1/8″ to 1/4″ (.3 to .6 cm) toe out. This means the
measurement at the front of the tire (A) is 1/8″ to 1/4″ (.3 to .6 cm) wider than the measurement at the rear (B).

Chalk Line
Measurement
“A”

Measurement “B”

TOE ALIGNMENT ADJUSTMENT

1. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you
which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie
rod(s) need adjustment.

CAUTION: During tie rod adjustment it is very important that the following precautions be taken when tightening
tie rod end jam nuts. If the rod end is positioned incorrectly it will not pivot, and may break.

To adjust toe alignment:
Hold tie rod end to keep it from rotating.

Loosen jam nuts at both end of the tie rod.

Shorten or lengthen the tie rod until alignment is as required
to achieve the proper toe setting as specified in Method
1 (1/16″ to 1/8″) or Method 2 (1/8″ to 1/4″).

When the tie rod end jam nuts are tightened, be sure to hold
tie rod ends so they are parallel with the steering arm or the
steering frog, respectively, to prevent rod end damage.

2. After alignment is complete, torque jam nuts to 33-40 ft.
lbs. (45-55 Nm).

Hold
Rod End

Correctly
Tightened
Jam Nut

Incorrectly
Tightened
Jam Nut

1.28

CHAPTER 2
ENGINE

Torque Specifications 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Special Tools, Engine 2.1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Installation Notes 2.2. . . . . . . . . . . . . . . . . . . . . . . . .

Engine Disassembly 2.3-2.12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Inspection 2.13-2.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Honing 2.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft Runout Inspection 2.17. . . . . . . . . . . . . . . . . . . . .

Engine Assembly 2.18-2.16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Plug Fouling 2.27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Troubleshooting 2.28-2.29. . . . . . . . . . . . . . . . . . . . . . . . . .

2

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)

Flywheel 25 ft.lbs (34 Nm)

Oil Drain Bolt (Transmission) 14 ft.lbs (19 Nm)

Oil Pump Bolts 43 in.lbs (5 Nm)

Fan Housing 84 in.lbs (9.5 Nm)

Fan Bolts 84 in.lbs (9.5 Nm)

Stator Plate 84 in.lbs (9.5 Nm)

Starter Motor Bolts 84 in.lbs (9.5 Nm)

Spark Plug 11 ft.lbs (15 Nm)

SPECIAL TOOLS

PART NUMBER DESCRIPTION

0450697 Crankshaft Removal Tool (TE0210)

0450698 Flywheel Puller (TE040)

0450699 Oil Pump Drive Gear Removal Tool (TE041)

0450700 Crankcase Separating Tool (TE310)

2.1

ENGINE

ENGINE INSTALLATION NOTES

General Items

1. Install previously removed components using new gaskets, seals, and fasteners where applicable.

2. Perform regular checks on fluid levels, controls, and all important areas on the vehicle as outlined in the daily
pre-ride inspection checklist.

Exhaust

1. Replace exhaust gaskets. Seal connections with high temp silicone sealant.

2. Check to be sure all springs are in good condition.

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.

2. Use fuel with a minimum octane of 87 (R+M)/2 method.

2.2

ENGINE DISASSEMBLY

Fan Cover and Cylinder Air Shroud

1. Remove the fasteners on fan cover.

2. Remove cylinder air shroud and deflector.

ENGINE

3. Loosen bolts securing fan and remove fan.

Starter Motor

4. Remove starter motor.

2.3

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. Always replace the
reed valve gasket when removing.

NOTE:Check the condition of the reed. If petals look
damaged in any way, replace.

Muffler, Cylinder and Cylinder Head

8. Remove spark plug. Check the electrode for carbon
and wear. Spark plug gap should be .024-.028″
(.6-.7 mm).

Spark Plug Gap:

024-.028I (.6-.7 mm)

2.4

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.

ENGINE

Piston Pin, Piston and Rings

11. Remove piston pin circlips.

12. Remove piston pin and piston. Use care not to
damage piston or pin. Inspect piston for scoring.

2.5

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). Remove
gasket and discard.

2.6

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.

ENGINE

17. Remove drive clutch nut.

18. Remove one-way clutch washer.

19. Remove the primary fixed sheave and claw washer.

2.7

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. Remove the plate, shaft pin, washers, and idle gear.

2.8

ENGINE DISASSEMBLY, CONT.

25. Remove the starter clutch, starter gear, needle
bearing, and washer.

Driven Shaft Assembly

26. Drain the oil from gear case.

ENGINE

27. Remove transmission cover and gasket.

28. Remove the driven clutch shaft components and
shaft assembly.

Drain Plug

2.9

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. Remove stator assembly.

2.10

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:

ENGINE

PN 0450699

34. Loosen the bolts and remove the bracket.

2.11

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. Remove the external snap ring on the output shaft
bearing and remove the oil seal.

2.12

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″ (0.05 mm) or less. If gap is excessive,
resurfacing head or replacement is needed.

Cylinder Head Warp
Service Limit:
.002I (0.05 mm)

Cylinder Inspection

2. Inspect the surface of the cylinder 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″ (0.05
mm) or less. If gap is excessive, resurfacing
cylinder or replacement is needed.

ENGINE

Cylinder Warp
Service Limit:
.002I (0.05 mm)

3. Inspect the cylinder walls for damage or scoring.
The cylinder bore must be de-glazed whenever new
piston rings are installed. If cylinder wear or
damage is excessive, it will be necessary to
oversize the cylinder using a new oversize piston
and rings. See Honing to Oversize in this chapter.
Inspect cylinder for out of round.

PIston Inspection

4. Inspect the piston for scoring or cracks in piston crown
or pin area. Excessive carbon buildup below the ring
land is an indication of piston, ring, or cylinder wear. If
damage is excessive, replace piston. Piston-to-cylinder
clearance should not exceed .0047″ (0.12 mm).
Measure the piston 5/8″ (15 mm) from bottom. Then
measure inside diameter of cylinder. The difference
between these measurements should not exceed
.0047″ (0.12 mm).

Piston to Cylinder Clearance:

.0047I (0.12 mm)

5/8″ (15 mm)

2.13

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.

Piston Ring Installed Gap
Service Limit:
.030I (0.75 mm)

PIston Pin Hole Inspection

2. Using a telescoping gauge or similar bore gauge,
measure the inside diameter of the piston pin hole
on both sides of the piston. Replace if diameter
exceeds .395″ (10.03 mm)

Piston Pin Hole
Service Limit:
.395I (10.03 mm)

PIston Pin Inspection

3. Inspect the surface of the piston pin for damage.
Measure the diameter of the piston pin in three
areas with a micrometer. The service limit for the
piston pin is .393″ (9.980 mm).

Piston Pin
Service Limit:
.393I (9.980 mm)

Connecting Rod Inspection

4. Inspect the inner surface of the small end of the
connecting rod for wear or damage. Oil and install
needle bearing and pin in connecting rod. Rotate
pin slowly and check for rough spots or any
resistance to movement. Replace both pin and
bearing if there is any resistance to rotation.
Measure the inner diameter of the small end of the
connecting rod. The service limit is .553″ (14.04
mm.)

Connecting Rod Small End
Service Limit
.553I (14.04 mm)

2.14

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
attempt to reverse the reeds to reduce the air gap.

Always replace them if damaged.

reed for stress marks or missing material.

Reed Valve Air Gap
Service Limit:
.015I (0.4 mm)

Clutch Cover and Brake Lining

2. Inspect the condition of the clutch cover. Measure
the inside diameter of the cover using a caliper. The
inner diameter service limit is 4.43″ (112.5 mm).
Inspect the condition and diameter of the brake
lining. The service limit of the lining is .039″ (1.0
mm). If either of these measurements exceeds the
limit, replace the clutch cover.

Clutch Cover Inner Diameter
Service Limit: 4.43I (112.5 mm)

Check each fiber

Reed Pedal
Clearance .015
(.38 mm) max.

″

.039″ (1.0 mm)

ENGINE

Exaggerated
for illustration

Brake Lining
Service Limit: .039″ (1.0 mm)

Compression Spring

3. Use a vernier caliper to inspect the length of the
compression spring. With the spring at full
extension, the measurement should be no less than

2.74″ (69.7 mm). If out of specification, replace
spring.

Compression Spring
Service Limit:

2.74I (69.7 mm)

Belt Inspection

4. Inspect the surface of the drive belt for uneven wear
or grease deposits. Using a vernier caliper,
measure the width of the belt. The service limit of
the belt is .626″ (15.9 mm). If the width of the belt is
less than the service limit, or if the belt is worn,
glazed or hourglassed, replace.

Drive Belt Width
Service Limit
.626I (15.9 mm)

2.15

ENGINE

CYLINDER HONE SELECTION/HONING PROCEDURE

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.

Cylinders may be wet or dry honed depending upon the hone manufacturer’s recommendations. Wet honing re­moves more material faster and leaves a more distinct pattern in the bore.

CAUTION:

HONING TO OVERSIZE

If cylinder wear or damage is excessive, it will be nec­essary to oversize the cylinder using a new oversize
piston and rings. This may be accomplished by either
boring the cylinder and then finish honing to the final
bore size, or by rough honing followed by finish honing.

For oversize honing always wet hone using honing oil
and a coarse roughing stone. Measure the piston (see
piston measurement) and rough hone to the size of the
piston. Always leave .002 - .003″ (.05 - .07 mm) for fin-
ish honing. Refer to piston-to-cylinder clearance spec­ifications on page 2.13 before honing. Complete the
sizing with fine grit stones to provide the proper cross­hatch finish and required piston clearance.

EXAMPLE OF CROSS HATCH PATTERN

A finished cylinder should have a cross-hatch pattern to ensure piston ring seating and to aid in the retention of
the fuel/oil mixture during initial break in. Hone cylinder according to hone manufacturer’s instructions, or these
guidelines:

S Use a motor speed of approximately 300-500 RPM, run the hone in and out of the cylinder rapidly until cutting

tension decreases. Remember to keep the hone drive shaft centered (or cylinder centered on arbor) and to
bring the stone approximately 1/2″ (1.3 cm) beyond the bore at the end of each stroke.

S Release the hone at regular intervals and inspect the bore to determine if it has been cleared, and to check

piston fit. NOTE: Do not allow cylinder to heat up during honing. The thinner areas of the liner around the
ports will expand causing uneven bore.

S After honing has been completed inspect all port opening areas for rough or sharp edges. Apply a slight cham-

fer to all ports to remove sharp edges or burrs, paying particular attention to the corners of the intake and
exhaust ports.

IMPORTANT:

CLEANING THE CYLINDER AFTER HONING

It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material. Wash the cylinder
in a solvent, then in hot, soapy water. Pay close attention to areas where the cylinder sleeve meets the aluminum
casting (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly,
dry with compressed air, and oil the bore immediately with Polaris 2 Cycle Lubricant.

2.16

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.

MAG Side PTO Side

HIGH .004″ (.1mm)

HIGH .006″ (.150mm)

2.17

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.

6

Crankcase Bolt Torque:

86 in.lbs. (10 Nm)

3. Install the oil pump bracket inside the MAG side of
the crankcase.

4. Install the oil pump drive gear and new external
circlips.

4

1

5

2

3

2.18

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. (9.5 Nm)

ENGINE

7. Inspect flywheel key for damage. Replace if
necessary. Install flywheel and torque to
specification.

Flywheel Nut Torque:

25 ft.lbs. (34 Nm)

8. Install driven clutch shaft components and shaft
assembly.

2.19

ENGINE

ENGINE ASSEMBLY

9. Install new transmission cover gasket and install
transmission cover. Torque bolts to specification.

Transmission Cover Bolt Torque:

84 in.lbs. (9.5 Nm)

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.

12. Install the plate, shaft pin, washers, and idler gear.

13. Install idle gear bolts and torque to specification.

Idler Gear Bolt Torque:

2.20

84 in.lbs. (9.5 Nm)

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.

ENGINE

16. Install drive belt.

17. Install the primary fixed sheave and claw washer.

2.21

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.

Transmission Cover Bolt Torque:

84 in.lbs. (9.5 Nm)

20. Install new gasket, bolts grommets, protectors,
filter, and install carburetor tube bracket and cover
(Scrambler 50). Torque cover bolts to specification.

Transmission Cover Bolt Torque:

2.22

84 in.lbs. (9.5 Nm)

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.

ENGINE

23. Install new base gasket and carefully install new
piston and piston pin. Use care not to damage
parts.

24. Install new circlips.

2.23

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. (19 Nm)

27. Install new spark plug. Spark plug gap should be
.024-.028″ (.6-.7 mm).

Spark Plug Gap:

024-.028I (.6-.7 mm)

28. Install intake manifold and reed valve. Install bolts
securing the intake manifold. Torque to specification.

NOTE:Remove any remaining gasket material from the
reed valve housing and crankcase. Always replace the
reed valve gasket when removing.

NOTE:Check the condition of the reed. If petals look
damaged in any way, replace.

Intake Manifold Bolt Torque:

2.24

108 in.lbs. (12 Nm)

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.

ENGINE

31. Install starter motor. Torque bolts to specification.

Starter Motor Bolt Torque:

84 in.lbs. (9.5 Nm)

32. Install fan. Torque fan bolts to specification.

Fan Bolt Torque:

84 in.lbs. (9.5 Nm)

2.25

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

SPARK PLUG FOULING

S Spark plug cap loose or faulty

Choke cable adjustment or plunger/cable sticking

S
S Foreign material on choke plunger seat or plunger
S Incorrect spark plug heat range or gap
S Carburetor inlet needle and seat worn or leaking
S Jet needle and/or needle jet worn or improperly adjusted

Excessive carburetor vibration (loose or missing needle jet locating pins)

S
S Loose jets in carburetor or calibration incorrect for altitude/temperature
S Incorrect float level setting
S PVT system calibrated incorrectly or components worn or mis-adjusted
S Fuel quality poor (old) or octane too high
S Low compression

Restricted exhaust

S
S Weak ignition (loose coil ground, faulty coil, stator, or ETC switch)
S ETC switch mis-adjusted
S Restricted air filter (main or pre-cleaner) or breather system
S Improperly assembled air intake system
S Restricted engine breather system
S Oil contaminated with fuel
S Restricted oil tank vent

ENGINE

2.27

ENGINE

TROUBLESHOOTING

Engine Turns Over But Fails to Start

S No fuel
S Dirt in fuel line or filter
S Fuel will not pass through fuel valve

Fuel pump inoperative/restricted

S
S Tank vent plugged
S Carb starter circuit
S Engine flooded
S Low compression (high cylinder leakage)

No spark (Spark plug fouled)

S

Engine Does Not Turn Over

S Dead battery
S Starter motor does not turn
S Engine seized, rusted, or mechanical failure

Engine Runs But Will Not Idle

S Restricted carburetor pilot system
S Carburetor misadjusted
S Choke not adjusted properly
S Low compression
S Crankcase breather restricted

Engine Idles But Will Not Rev Up

S Spark plug fouled/weak spark
S Broken throttle cable
S Obstruction in air intake
S Air box removed (reinstall all intake components)
S Incorrect or restricted carburetor jetting
S Incorrect ignition timing
S Restricted exhaust system

Engine Has Low Power

S Spark plug fouled
S Cylinder, piston, ring, wear or damage (check compression)
S PVT not operating properly
S Restricted exhaust muffler
S Dirty carburetor

Piston Failure - Scoring

S Lack of lubrication
S Dirt entering engine through cracks in air filter or ducts

2.28

TROUBLESHOOTING, CONT

Excessive Smoke and Carbon Buildup

S Excessive piston-to-cylinder clearance

S Worn rings, piston, or cylinder

Air filter dirty or contaminated

S

Low Compression

S Cylinder head gasket leak

S Cylinder or piston worn

S Piston rings worn, leaking, broken, or sticking

Backfiring

S Fouled spark plug or incorrect plug or plug gap

S Carburetion faulty - lean condition

S Exhaust system air leaks

ENGINE

S Ignition system faulty:

Spark plug cap cracked/broken
Ignition coil faulty
Ignition or kill switch circuit faulty
Ignition timing incorrect
Sheared flywheel key

S Poor connections in ignition system

S System wiring wet

S Lean condition

Overheating

S Lean mixture (restricted jets, vents, or fuel valve)

S Dirt in cooling fins

S Ignition timing misadjusted

S Spark plug incorrect heat range

2.29

CHAPTER 3
FUEL SYSTEM/CARBURETION

Fuel System Warnings 3.1. . . . . . . . . . . . . . . . . . . . . . . .

Carburetor Operation 3.2. . . . . . . . . . . . . . . . . . . . . . . . .

Float System 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pilot Jet / Pilot Air Screw / Air/Fuel Mixture 3.3. . . . . . .

Jet Needle / Needle Jet / Throttle Opening 3.4. . . . . . .

Throttle Valve / Main Jet 3.5. . . . . . . . . . . . . . . . . . . . . . .

Pilot System 3.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Slide Cutaway / 1/8-3/8 Throttle 3.7. . . . . . . . . . . . . . . .

Jet Needle / Needle Jet / 3/8-3/4 Throttle 3.8. . . . . . . .

Main System / 3/4 to Full Throttle 3.9. . . . . . . . . . . . . . .

Fuel Delivery 3.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vent Systems / Float Height 3.11. . . . . . . . . . . . . . . . . . . .

Needle and Seat Leakage Test 3.11. . . . . . . . . . . . . . . . .

Carburetor Float Bowl Draining 3.12. . . . . . . . . . . . . . . . .

Carburetor Exploded View 3.13. . . . . . . . . . . . . . . . . . . . .

Troubleshooting 3.14-3.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

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.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison­ous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine is hot. Severe burns may result.

3.1

FUEL SYSTEM/CARBURETION

CARBURETOR OPERATION

The function of a carburetor is to produce a com­bustible 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. A proper ratio means an ideal air/fuel
mixture which can burn without leaving an excess
of fuel or air. Whether the proper mixture ratio is
maintained or not is the key to efficient engine op­eration.

The engine of a vehicle is operated under a wide
range of conditions, from idling with the throttle
valve remaining almost closed, to full load or
maximum output with the throttle valve fully
opened. In order to meet the requirements for the
proper mixture ratio under these varying condi­tions, a low speed fuel system, or pilot system,
and a main fuel system are provided in these type
of carburetors.

This carburetor has varying operations depend­ing upon varying driving conditions. It is
constructed of a float system, pilot system, main
system, and starter system or initial starting de­vice.

Fuel Supply

Constant
Fuel Level

Float

Idle Adjustment
Screw

Float Guide
Pin

Needle Valve

Float Arm

FLOAT SYSTEM

The float system is designed to maintain a
constant height of gasoline during operation.
When the fuel flowing from the fuel pump into the
float chamber through the needle valve reaches
the constant fuel level, the floats rise. When the
buoyancy of the float and the fuel pressure of the
fuel pump balance, the needle valve seals the ori­fice in the needle seat, preventing further fuel de­livery, and the level of fuel in the bowl remains rel­atively constant.

The fuel level in the bowl assists in controlling the
amount of fuel in the fuel mixture. Too high a level
allows more fuel than necessary to leave the
nozzle, enriching the mixture. Too low a level re­sults in a leaner mixture, since not enough fuel
leaves the nozzle. Therefore, the predetermined
fuel level should not be changed arbitrarily.

3.2

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 inter­val under a given set of conditions.

PILOT AIR SCREW

The pilot air screw controls the fuel mixture from idle to low
speeds. The tapered tip of the air screw projects into the air
passage leading to the pilot jet air bleeds. By turning the
screw in or out, the cross sectional area of the air passage
is varied, in turn varying the pilot jet air supply and changing
the mixture ratio.

FUEL SYSTEM/CARBURETION

Pilot Jet
Indicator
Number

Pilot Air Screw

AIR/FUEL MIXTURE RATIO

A carburetor with a piston type throttle valve is also called
a variable venturi type carburetor. In this type of carburetor,
the needle jet and jet needle serve to control a proper air/
fuel mixture ratio at the medium throttle valve opening (be­tween 1/4 and 3/4 opening). Having the proper needle jet
and jet needle has a major impact on engine performance
at partial load.

The jet needle tapers off at one end and the clearance be­tween the jet needle and the needle jet increases as the
throttle valve opening gets wider. The air/fuel mixture ratio
is controlled by the height of the “E” ring inserted into one
of the five slots provided in the head of the jet needle. The
chart at right shows the variation of fuel flow based on the
height of the “E” ring.

E-Clip Position Vs. Fuel Flow

2

3
4

4

3

2

15

50 75 100%

Throttle Valve Opening

3.3

FUEL SYSTEM/CARBURETION

JET NEEDLE

The jet needle has five adjustment grooves cut into the up­per 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
extends into the needle jet. Fuel flows through the space
between the needle jet and jet needle. This space does not
vary until the throttle reaches the 1/4 open point. At that
time the tapered portion of the needle begins to move out
of the jet, affecting fuel flow as the opening enlarges. If the
needle clip is changed from the standard position to a lower
groove, the needle taper starts coming out of the jet sooner,
resulting in a richer mixture. Moving the clip higher pro­duces a leaner mixture. If the taper is worn due to vibration,
fuel flow may be significantly affected.

NEEDLE JET

The needle jet works in conjunction with the jet needle to
regulate fuel flow rate. An air bleed opening in the side of
the needle jet brings in air measured by the air jet. This air
initiates the mixing and atomizing process inside the needle
jet. Mixing is augmented by a projection at the needle jet
outlet, called the primary choke. The letter number code
stamped on the jet indicates jet inside diameter.

Jet Needle

Leaner

Groove

Richer

Opening faces
engine

Needle Jet

THROTTLE OPENING VS.
FUEL FLOW

In a full throttle condition the cross sectioned area be­tween the jet needle and the needle jet is larger than
the cross sectioned area of the main jet. The main jet
therefore has greater control over fuel flow.

Closed
Throttle

Small
Clearance

One-half
Throttle

Medium
Clearance

Full
Throttle

Washer

Main Jet

Large
Clearance

3.4

FUEL SYSTEM/CARBURETION

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
by the cutaway. By controlling air flow the negative
pressure over the needle valve is regulated, in turn
varying the fuel flow.

The throttle valves are numbered 1.0, 1.5, 2.0, etc.,
according to the size of the cutaway. The higher the
number, the leaner the gasoline/air mixture.

MAIN JET

When the throttle opening becomes greater and the
area between the needle jet and jet needle increases,
fuel flow is metered by the main jet. The number on the
jet indicates the amount of fuel CCs which will pass
through it in one minute under controlled conditions.
Larger numbers give a greater flow, resulting in a
richer mixture.

Main jets are screwed directly into the needle jet base.

Throttle Valve

Engine Side

Higher cutaway number = leaner mixture

Main Jet

Hex Style
Main Jet

Air Box Side

Cutaway

Larger Number = Richer Mixture

3.5

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.

The mixture is regulated to some degree by adjusting the air screw. When the air screw is closed, the fuel mixture
is made richer as the amount of air is reduced. When the air screw is opened, the mixture is made more lean
as the amount of air is increased.

Throttle Valve

Throttle Stop (Idle Speed) Screw

Pilot Jet

By­pass

Pilot Outlet

Air Screw

3.6

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. A flat angle would provide a much richer mixture because there is
more resistance to air flow. The venturi shape can be adjusted for each engine’s breathing characteristics by
using a different valve cutaway angle. A number will be stamped into the bottom of the valve (e.g. 2.5) indicating
the size of the cutaway. The higher the number, the steeper the angle.

Cutaway Angle

Throttle Valve

Jet Needle

Air Jet

By-pass

Air Box Side

Pilot Outlet

Engine Side

Pilot Jet

Needle Jet

Main Jet

3.7

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 adjust­ment 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. Moving the clip up lowers the needle in the jet passage
and leans the mixture. Letter and number codes are stamped into the needle and the jet indicating sizes and
tapers of each.

Clip Position
(Shown in #3)

Throttle Valve

Air Box Side

Leaner

Richer

Air Jet

Jet Needle

By-pass

Pilot Outlet

Engine Side

Pilot Jet

Needle Jet

Main Jet

1

3

5

2

4

Jet Needle “E” Clip Position

3.8

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. This
system works in conjunction with the needle jet system.

During low speed driving, there is very little clearance between the jet needle and the needle jet; therefore, very
little fuel from the main jet can pass between the jet needle and the needle jet. As the throttle valve opening is
increased, the tapered jet needle is raised farther out of the needle jet, allowing greater fuel flow. Under full throttle
opening, the cross sectioned area of clearance between the jet needle and the needle jet becomes greater than
the cross sectioned area of the main jet. Thus the main jet is now controlling the amount of fuel flow.

Throttle Valve

Air Box Side

Air Jet

Jet Needle

By-pass

Pilot Outlet

Engine Side

Pilot Jet

Needle Jet

Main Jet

3.9

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.

The throttle valve controls the rate of engine air by its movement up and down in the carburetor venturi. At small
throttle openings the air flow is regulated chiefly by the valve cutaway, with greatest effectiveness at 1/4 throttle
opening. Throttle valves are numbered 1.0, 1.5, 2.0, etc., according to the size of the cutaway. Decreasing the
cutaway number will increase the amount of fuel delivered in its effective range.

The jet needle and needle jet have an effective operating range from approximately 1/8 to 7/8 throttle opening.
The amount of fuel delivered during this range relies upon the jet needle clip position, as well as the needle jet
size and other specifications.

The main jet affects fuel delivery at 1/4 throttle and consistently increases to full throttle opening.

INCREASINGDECREASING

EFFECT

THROTTLE OPENING - 2 Cycle

Throttle Valve Cut-Away
Jet Needle/Needle Jet

Carburetor Component Function - 2 Cycle

System Main Components Main Function Main Affect

Float System (Fuel Level
Control)

Venting Vent Passages in Carbure-

Starter (Choke/Enrichment) Choke Lever, Cable, Choke

Pilot (Idle System) Pilot Jet/Passageways, Pilot

Main System Main Jet, Main Air Passage,

Inlet Pipe, Needle and Seat,
Floats, Float Pins

tor, Vent line

Plunger, Return Spring,
Carb Passages (Starter Jet,
passage in float bowl)

Air Screw with Spring, By­pass Port (Beneath Throttle
Slide), Air Jet, Pilot Outlet,
Throttle Valve Cutaway

Needle Jet, Jet Needle,
Throttle Valve

Maintains specified fuel lev­el in float chamber (carbure­tor float bowl)

Supplies atmospheric pres­sure to fuel in float chamber

Supplies additional fuel air
mixture necessary for cold
starting

Primarily supplies fuel at idle
and low throttle settings

Supplies fuel at mid-range
and high throttle settings.

All systems
All throttle ranges

All systems
All throttle ranges

All throttle ranges
Greatest effect at low
throttle settings and idle
speeds

Mainly idle to 1/4 throttle
Minimal effect after 1/2
throttle

1/4 to full throttle

3.10

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 carbu­retor or fuel tank.

FLOAT HEIGHT

1. Invert the carburetor and remove float bowl.

2. Rest the float tongue lightly on the inlet needle valve
pin without compressing the spring.

3. Measure height from float bowl mating surface to float
arm as shown. Both sides of float arm must be parallel
to each other. Use float adjustment tool (PN 2872314)
or a vernier caliper. When measuring height, be sure
inlet needle valve spring is not compressed. If
adjustment is necessary, bend the tongue slightly.

Float Height:

Parallel to Gasket Surface ± 1mm

Float Arm

Gasket
Surface

Parallel

NEEDLE AND SEAT LEAKAGE TEST

1. Install the float bowl. Invert the carburetor and install
a Mity-Vac (PN 2870975) to the fuel inlet fitting.
Apply 5 PSI pressure to inlet fitting. The needle and
seat should hold pressure indefinitely. If not, inspect
needle and seat and seat O-ring or gasket.

3.11

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 ex­tended periods of storage.

NOTE: A drain plug is located on the side of the float bowl.

1. Turn fuel valve to the off position.

2. Place a clean container beneath the bowl drain spigot
or bowl drain hose.

3. Loosen drain plug and allow fuel in the float bowl and
fuel line to drain completely.

4. Inspect the drained fuel for water or sediment.

5. TIghten drain plug.

6. Turn fuel valve to “on”.

7. Inspect carburetor for fuel leaks.

8. Start machine and re-check for leaks.

RES

OFF

ON

3.12

FUEL SYSTEM/CARBURETION

3.13

1. Carburetor Assembly

2. Gasket

3. Throttle Spring

4. Bolt

5. Washer

6. Valve, Throttle

7. Jet Needle

8. Needle Jet

9. Seal, Float Chamber

10. Main Jet

11. Overflow Tube

12. Pilot Jet

13. Pilot Air Screw

14.Drain Plug

15. Bolt

16. Washer .

17.Bolt

18. Starter Plunger

19.O-ring

20. Throttle Screw

21. Needle and Seat

22. Float Pin

23. Cable Adjuster Nut

Carburetor Exploded View

1

2

3

4

5

Jet Needle “E”
Clip Position

Use a spring loaded center punch to

remove press-fit float pin.
NOTE:Set the center punch to the softest setting
(if adjustable) to avoid damage to float pin tower.

23

2

4

5

3

7

18

15

16

19

6

13

20

1

9

12

8

10

21

17

22

14

11

4

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.

S No fuel in tank
S Restricted tank vent, or routed improperly
S Fuel lines or fuel valve restricted
S Fuel filter plugged
S Carburetor vent line(s) restricted
S Plugged or restricted inlet needle and seat screen or inlet passage
S Clogged jets or passages
S Float stuck, holding inlet needle closed or inlet needle stuck
S Float level too low
S Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover)
S Jet needle position incorrect
S Incorrect pilot screw adjustment

RICH MIXTURE

Symptoms: Fouls spark plugs, black, sooty exhaust smoke, rough idle, poor fuel economy, engine runs rough/

misses, poor performance, bog, engine loads up, backfire.

S Air intake restricted (inspect intake duct)
S Air filter dirty/plugged
S Choke plunger sticking, incorrectly adjusted choke
S Choke cable binding or improperly routed
S Incorrect pilot air/fuel screw adjustment
S Faulty inlet needle and seat
S Faulty inlet needle seat O-Ring
S Float level too high
S Poor fuel quality (old fuel)
S Loose jets
S Worn jet needle/needle jet or other carburetor parts
S Dirty carburetor (air bleed passages or jets)
S Fouled spark plug

POOR IDLE

Symptoms: Idle too high.

S Idle adjusted improperly/idle mixture screw damaged
S Sticky throttle valve
S Throttle cable sticking, improperly adjusted, routed incorrectly
S Choke cable sticking, improperly adjusted, routed incorrectly

3.14

TROUBLESHOOTING

IDLE TOO LOW

S Choke cable incorrectly adjusted
S Idle speed set incorrectly
S Idle mixture screw misadjusted or damaged
S Belt dragging
S Ignition timing incorrect
S Worn jet needle/needle jet

ERRATIC IDLE

S Choke cable bending or incorrectly adjusted
S Throttle cable incorrectly adjusted
S Air leaks, dirty carburetor passages (pilot circuit)
S Pilot mixture screw damaged or adjusted incorrectly
S Tight valves
S Ignition timing incorrect
S Belt dragging
S Dirty air cleaner
S Engine worn
S Spark plug fouled
S Idle speed set incorrectly (speed limiter)
S Worn jet needle/needle jet

FUEL SYSTEM/CARBURETION

3.15

CHAPTER 4
BODY AND STEERING

Torque Specifications and Special Tools 4.1. . . . . . . . . . . .

Frame Photos 4.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Mounting 4.3-4.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shocks and Springs 4.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Suspension A-arms 4.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering 4.7-4.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Brake 4.9-4.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Brake and Axle 4.10-4.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel and Oil Tank 4.14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front and Rear Cab 4.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Handlebar 4.16-4.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Muffler 4.18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

BODY / STEERING / SUSPENSION

TORQUE SPECIFICATIONS

Front A-Arm Attaching Bolt 26-30 ft. lbs. (36-40 Nm). . . . . . . . . . . . . . . . . .

Handlebar Adjuster Block 84 in. lbs. (10 Nm). . . . . . . . . . . . . . . . . . .

Rear Shock Bolts 25 ft. lbs. (35 Nm). . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear Wheel Hub Nut 78-81 ft. lbs. (108-112 Nm). . . . . . . . . . . . . . . . . . . . . . .

Front Shock Bolts 15 ft. lbs. (20 Nm). . . . . . . . . . . . . . . . . . . . . . . . . .

Swing Arm Mounting Bolt 26-30 ft. lbs. (36-40 Nm). . . . . . . . . . . . . . . . . . . .

Inner Tie Rod Bolts 33-40 ft. lbs. (45-55 Nm). . . . . . . . . . . . . . . . . . . . . . . . .

Outer Tie Rod Bolts 33-40 ft. lbs. (45-55 Nm). . . . . . . . . . . . . . . . . . . . . . . .

Tie Rod Jam Nuts 12-14 ft. lbs (17-19 Nm). . . . . . . . . . . . . . . . . . . . . . . . . .

Motor Mount Bolts-M8 22-25 ft. lbs (30-35 Nm). . . . . . . . . . . . . . . . . . . . . .

Motor Mount Bolts-M10 33-40 ft. lbs (45-55 Nm). . . . . . . . . . . . . . . . . . . . .

Spindle Nuts 40-45 ft. lbs (58-62 Nm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Post Mount Nuts 103 in. lbs (11.6 Nm). . . . . . . . . . . . . . . . . . .

Steering Post Nut 62-65 ft. lbs (86-90 Nm). . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Nuts 62-65 ft. lbs (86-90 Nm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sprocket Bolts 18 ft. lbs (25 Nm). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain Tensioner Bolt 84 in. lbs (10 Nm). . . . . . . . . . . . . . . . . . . . . . . .

Bearing Carrier Mounting Bolts 43 ft. lbs (60 Nm). . . . . . . . . . . . . . .

Rear Cover Mounting Bolts 84 in. lbs (10 Nm). . . . . . . . . . . . . . . . . .

Fuel Tank Mounting Bolts 103 in. lbs (12 Nm). . . . . . . . . . . . . . . . . . . .

Oil Tank Mounting Bolts 103 In. lbs (12 Nm). . . . . . . . . . . . . . . . . . . . .

Front Bumper Mounting Bolts 103 in. lbs (12 Nm). . . . . . . . . . . . . . . .

Cab Mounting Bolts 103 in. lbs (12 Nm). . . . . . . . . . . . . . . . . . . . . . . . .

Muffler Mounting Bolts 25 ft. lbs (34 Nm). . . . . . . . . . . . . . . . . . . . . .

NOTE: Refer to exploded views throughout this chapter for identification and location of components.

SPECIAL TOOLS

Description Part No.

Shock Spanner Wrench 2870872. . . . . . . . . . . . . .

Shock Spring Compressor Tool 2870623. . . . . . .

4.1

BODY / STEERING / SUSPENSION

FRAME PHOTOS

Side View

4.2

Front View

Rear View

ENGINE MOUNTING

BODY / STEERING / SUSPENSION

Mount Tube

Rubber Bushings

Engine Bracket

Rubber Bushing

4.3

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.

4. Insert the engine into the frame body. Mount to the
brackets including the fix tube, spacer tube, and
engine holder seat.

Motor Mount Bolt Torque:
M10= 33-40 ft.lbs. (45-55 Nm)
M8= 22-25 ft.lbs. (30-35 Nm)

2

3

1

4.4

SHOCKS AND SPRINGS

Front Shocks and Springs

BODY / STEERING / SUSPENSION

Rear Shock and Spring

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.

2. The rear shock and spring is mounted to the frame
and swing arm. The rear spring can be adjusted for
more or less spring preload depending on rider
preference.

4.5

BODY / STEERING / SUSPENSION

SUSPENSION A-ARMS

Upper Spindle Bushing

Grease Fitting

Grease
Fitting
Cap

Lower Spindle Bushing

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. Torque the bolts to specification.
Mount the shock in the A-arm and torque bolt to
specification.

Right A-arm

Bushings

Left Spindle

Left A-arm

A-arm Mounting Bolt Torque:
26-30 ft.lbs. (36-40 Nm)
Shock Mounting Bolt Torque:
15 ft.lbs. (20 Nm)

2. Grease spindles and mount the spindles on the
A-arms. The spindle marked “R” is for right side,
and “L” for left side. Torque the spindle nut to
specification. Insert cotter key.

Spindle Nut Torque:
40-45 ft.lbs (58-62 Nm)

A-arm Bolts

4.6

STEERING

Steering Post Bushings

BODY / STEERING / SUSPENSION

Steering Post Sleeve

Right Tie Rod Asm.

Steering Post

Left Tie Rod Asm.

Seal

Circlip

Bearing

Seal

Spacer

Washer

Nut

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.

Steering Post Mount Nut Torque:
103 in.lbs. (11.6 Nm)

4.7

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
binding.

3. Mount the tie rod to the steering post and to the
spindle. Mount the tie rod so that the end with the
flats is toward the spindle.

Steering Nut Torque:
62-65 ft.lbs. (86-90 Nm)

Steering Post Nut

Tie Rod

4. Tighten inner and outer tie rod bolts to
specification.

Inner Tie Rod Bolt Torque:
33-40 ft.lbs (45-55 Nm)
Outer Tie Rod Bolt Torque:
33-40 ft.lbs (45-55 Nm)

Tie Rod Jam Nut Torque:
12-14 ft.lbs (17-19 Nm)

Steering Nut

A-arm

Tie Rod

Spindle

4.8

FRONT BRAKE

Brake Shoes

Retainer
Spring

Right Brake Plate

BODY / STEERING / SUSPENSION

Brake Cable

Return
Spring

Right Brake Arm Left Brake Arm

Brake Cam Shaft

Left Brake Plate

Brake Shoes

Retainer
Spring

1. Front brake backing plate assembly components.

2. Front brake shoe and brake drum. There are oil
seals and bearings in the front brake drums. Upon
disassembly, inspect the bearings and seals for
damage. Replace bearings and seals if
necessary.

Brake Plate

Brake Arm

Brake Cam Shaft

Brake Shoe Brake Drum

Return Spring

4.9

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. Connect the brake cable with brake arm.

6. Install the rubber cap.

REAR BRAKE AND AXLE

Rear Brake Drum

Brake Shoes

Brake Cam Shaft

Protective Cover

Rear Cover Plates

Rear Brake Cable

Rubber Gasket

Brake Arm Spring

Rear Brake Arm

Bearing Carrier

4.10

Spacer Tube

Rear Cover

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 protec­tor.

2. Install the swing arm to the frame and tighten the
mounting bolt to specification. Install rear shock
and spring. Tighten shock mounting bolts to
specification.

Swing Arm Mounting Bolt Torque:
26-30 ft.lbs. (36-40 Nm)
Rear Shock Mounting Bolt Torque:
25 ft.lbs. (35 Nm)

BODY / STEERING / SUSPENSION

3. Inspect the protective rubber gasket on the rear
brake drum for damage. Replace if needed.
Mount the rear brake plate, shoes, and springs on
the bearing carrier. Install the brake drum.

4. Install the rear axle bearing carrier and rear brake
assembly on swing arm.

Rear Brake Plate

Rear Brake Drum

Rear Brake Shoes

4.11

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. Install the drive sprocket on the rear wheel axle.

7. Install the right and left spacer tube on the rear
wheel axle.

8. Install the wheel hub and tighten axle nut to
specification.

Axle Nut Torque:
78-81 ft.lbs. (108-112 Nm)

Spacer Tube

4.12

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. Turn the
adjuster until the chain tension is set. Tighten the
adjuster nuts.

Chain Tension Specification:
.40-.80″ (10-20 mm) slack
Chain Tensioner Nut Torque:
84 in.lbs. (10 Nm)

BODY / STEERING / SUSPENSION

12. Tighten all bearing carrier bolts to specification.

Bearing Carrier Bolt Torque:
43 ft.lbs. (60 Nm)

13. Install the rear cover. Torque bolts to
specification.

Rear Cover Bolt Torque:
84 in.lbs. (10Nm)

Chain Adjuster

Carrier Bolts

Rear Cover

Carrier Bolts

4.13

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. Install the oil tank to the frame and tighten bolts to
specification. Always fill the oil reservoir before
riding.

Oil Tank Mounting Bolt Torque:
103 in.lbs. (12 Nm)

3. The fuel petcock has “ON”, “OFF”, and “RES”.
Make note of these positions on the petcock.
Always turn fuel off when transporting an ATV.

RES

OFF

ON

4.14

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)

BODY / STEERING / SUSPENSION

2. There are three (3) mounting positions for the
front and rear cab to the frame. The front cab is
mounted on positions 1 and 2. The rear cab is
mounted on position 3.

3. Install the front and rear cab to the frame and
tighten the mounting bolts to specification.

Cab Mounting Bolt Torque:
103 in.lbs. (12 Nm)

2

1

3

4. The front cab mounts to the front bracket of the
frame.

Bolt

4.15

BODY / STEERING / SUSPENSION

HANDLEBAR

Handlebar Grip

Right Hand Control

Top Handlebar Clamp

Bottom Handlebar Clamp

Throttle Cable

1. The handlebar assembly includes the right and
left side brake levers and the left side control
switch.

Handlebar

Left Hand Control

Brake Lever

2. The left side control switch includes the engine
stop switch and start switch. There is a parking
brake on the left brake lever. It is designed for
safety assurance. Always engage the parking
brake when the vehicle is stopped and the engine
is shut off.

Start Switch

ON

OFF

Engine Stop Switch

4.16

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.

Front Brake Lever Free Play:

BODY / STEERING / SUSPENSION

.40-.80I (10-20 mm)

Front Brake Lever Travel:

50 cc= 1 1/8I (28 mm)
90 cc = 1 3/4″ (45 mm)

5. Install the rear brake cable.

Rear Brake Lever Free Play:

.40-.80I (10-20 mm)

Rear Brake Lever Travel:

50 cc= 1 1/8I (28 mm)
90 cc = 2 1/2″ (65 mm)

6. Open the throttle ETC switch box and lightly
grease the throttle cable (A). Install the throttle
able.

Electronic Throttle Control (ETC) Switch

(Cast Aluminum Throttle Housing)

A

ETC Micro
Switch Button

4.17

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. Tighten bolt to specification.

Muffler Mounting Bolt Torque:
25 ft.lbs. (34 Nm)

4.18

Muffler Bracket