Polaris Scrambler 50 (2003), Predator 90 (2003), Scrambler 90 (2003), Sportsman 90 (2003) Service Manual (PN 9918068) – Chapter 5 Electrical
ELECTRICAL
SPECIAL TOOLS
Fluke 73 Multitester PN 2870659.......
Strobe Timing Light PN 2870630..........
Tachometer PN 8712100 or.................
Christie Multi--Batttery Charger PN PV--63070
(Available from SPX 800--328--6657)
ELECTRICAL SERVICE
NOTES
Keep the following notes in mind when diagnosing an
electrical problem.
Refer to wiring diagram for stator and
electrical component resistance
specifications.
When measuring resistance of a
component that has a low resistance
value (under10 Ohms), remember to
subtract meter lead resistance from
the reading. Connect the leads
together and record the resistance.
The resistance of the component is
equal to tested value minus the lead
resistance.
Become familiar with the operation of
your meter. Be sure leads are in the
proper jack for the test being
performed (i.e. 10A jack for current
readings). Refer to the Owner’s
manual included with your meter for
more information.
Voltage, amperage, and resistance
values included in this manual are
obtained with a Fluke
Multimeter or a Tektronix
DMM155. Both of these meters are
acceptable for use when
diagnosing electrical problems.
Readings obtained with other
meters may differ.
Pay attention to the prefix on the
multimeter reading (K, M, etc.) and
the position of the decimal point.
For resistance readings, isolate the
component to be tested. Disconnect
it from the wiring harness or power
supply.
This ignition system timing is non
adjustable. The specifications on
page 1.3 are intended for reference
only.
PN 8712500
73 Digital
2003 MODEL YOUTH ATV
SPEED
Per ANSI / SVIA--1--2001 (sec. 6.1.3)
the AS DELIVERED TO THE CON-
SUMER: The speed of youth models is
restricted to under 10 MPH for the 50 cc
models and under 15 MPH for the 90 cc
models. The dealer CANNOT, under
any circumstances, either prior to the
sale or later, even at the consumers
request, remove or adjust any speed
limiting device. Any speed limiting device can only be removed or adjusted
by the consumer when they determine
their child is capable of the additional
speed. Per ANSI / SVIA--1--2001 (sec.
6.2) the unrestricted top speed is less
than 15 MPH for the 50 cc models and
less than 30 MPH for the 90 cc models.
RESTRICTION
SPEED CONTROL SYSTEMS
Electronic Speed Control System
2003 Polaris Youth ATVs are equipped with an
electronic speed control system, which controls the
engine RPM and 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 than 15 mph. With the
jumper removed, 50cc models will travel no faster
than 15 mph and 90cc models will travel no faster than
30 mph.
Jumper Removal and Installation
1. Remove the CDI and its rubber mounting strap
from the mounting tab, which is located on the
frame bulkhead near the steering post. It can be
accessed through the left front fender.
2. Remove the two screws (B) from the jumper to
remove or install the jumper. Reinstall the
screws.
3. Reinstall the CDI and mounting strap onto the
mounting tab.
5.2
ELECTRICAL
BRAKE LIGHT BULB
A
SPEED CONTROL SYSTEMS
Throttle Stop Speed Control System
Adjusting speed at the CDI is the recommended
method of speed control, but the throttle stop system
may also be used. Use the following procedure to
control how far the throttle opens.
1. Loosen the jam nut (A)
2. Turn the screw (B) inward to reduce speed or
outward to increase speed.
3. Tighten the jam nut after adjusting.
REPLACEMENT
If the brake light does not work the bulb may need to
be replaced.
Lens Cover
B
1. From the rear of the taillight remove two screws
holding lens cover in place and remove lens
cover.
2. Remove bulb and replace it with recommended
bulb. Apply Nyogel
3. Reinstall the lens cover removed in step 1.
4. Test the brakelight to see that it’s working.
BATTERY
Youth ATV batteries have been upgraded to a
maintenance--free unit with more reserve capacity. A
new battery holder was designed to accommodate
the battery’s larger size. For charging, it is
A
B
recommended to use the Christie Charger
(PA--37453) available from SPX.
Bulb
grease PN 2871329.
YOUTH ATV BATTERY CHARGING CHART
State of
Charge
100% 12.8-- 13
75% 12.5-- 12
50% 12.0-- 12
25% 11.5-- 12
0% 11.5 v or
Vol tage Action Charge Time*
.0v
.8v
.5v
.0v
less
Fully
Charged
Slight
Charge
Charge 5--11 Hours @
Charge 13+Hours @ 0.4A
Charge 20 Hours @ 0.4A
None Required
3-- 6 Hours @ 0.4A
0.4A
Check State
of Charge
Battery may
be Dead
5.3
ELECTRICAL
* Charging times can vary depending on type
of charger. Follow the charger instructions.
BATTERY ACTIVATION
WARNING
Battery electrolyte is poisonous. It contains
sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention.
Batteries produce explosive gases. Keep sparks,
flame, cigarettes, etc. away. Ventilate when
charging or using in an enclosed space. Always
shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
WARNING: The gases given off by a battery are
explosive. Any spark or openflame near a battery can
cause an explosion which will spray battery acid on
anyone close to it. If battery acid gets on anyone,
wash the affected area with large quantities of cool
water and seek immediate medical attention.
To ensure maximum service life and performance
from a new battery, perform the following steps.
NOTE: Do not activate the battery unless it will be put
into regular service within 30 days. Polaris Youth ATV
batteries are a maintenance--free design. Do not
attempt to add water or electrolyte.
NOTE: New batteries must be fully charged before
use or battery life will be significantly reduced
(10-30% of the battery’s full potential).
Battery
NOTE: Wear safety glasses and rubber protective
gloves when working with batteries.
2. Remove the protective strip from the top of the
battery. Insert the battery electrolyte funnel into
the battery holes.
3. Carefully press the battery electrolyte pack onto
the battery electrolyte funnel. The funnel will
puncture the seals on the electrolyte pack,
releasing electrolyte into the battery. Allow the
pack to drain for 20 minutes, periodically tapping
the sides to release any air--lock that may occur.
4. Properly dispose of the battery electrolyte pack.
Let battery set with the vent caps off for 30
minutes to allow full absorption of the electrolyte.
After 30 minutes , install the battery seal strip onto
the battery.
5. Charge the battery for 3 to 5 hours on the initial
charge using a Christie Multi Battery Charger or a
charger with an output 1/10th the amp rating of
the battery.
Electrolyte
Funnel
BATTERY TERMINALS/
TERMINAL BOL
Use corrosion resistant Dielectric Grease (PN
2871329) on battery bolts.
TS
1. Remove the battery, battery acid, and
accessories from the box.
5.4
ELECTRICAL
BATTERY INSPECTION/
REMOV
NOTE: Polaris Youth ATVs use a maintenance free
battery. Do not remove the battery cap strip to check
the acid level. Perform the proper battery tests and
replace the battery as needed.
The battery is located under the seat.
Battery
1. Remove the rubber strap.
2. Disconnect battery negative (-) (black) cable first,
followed by the positive (+) (red) cable.
CAUTION
Whenever removing or reinstalling the battery,
disconnect the negative (black) cable first and
reinstall the negative cable last.
AL
BATTERY INSTALLATION
1. Clean battery cables and terminals with a stiff wire
brush. Corrosion can be removed using a
solution of one cup water mixed with one
tablespoon baking soda. Rinse will with clean
water and dry thoroughly.
2. Reinstall battery, attaching positive (+) (red) cable
first and then the negative (-) (black) cable. Coat
terminals and bolt threads with Polaris dielectric
grease (PN 2871027).
3. Route cables so they are tucked away in the
battery compartment.
4. Reinstall the rubber strap.
!
Do not start the engine with the battery
disconnected. Vehicle lamps will burn out if battery is
disconnected during vehicle operation.
Rubber Strap
BATTERY TESTING
Whenever a service complaint is related to either the
starting or charging systems, the battery should be
checked first.
Following are two tests which can easily be made on
a battery to determine its condition: OCV Test and
Load Test.
OCV - OPEN CIRCUIT
VOLTAGE
Battery voltage should be checked with a digital
multitester. Readings of 12.5 or less require further
battery testing and charging. See open circuit voltage
chart and Load Test.
NOTE: Batteries should be kept at or near a full
charge as possible. If the battery is stored or used in
a partially charged condition, crystal sulfation will form
on the plates, reducing the efficiency and service life
of the battery.
OPEN CIRCUIT VOLTAGE
State of
charge
100% Charged
75% Charged
50% Charged
25% Charged
0% Charged
TEST
Maintenence Free
Batteries
12.8--13.0V
12.5--12.8V
12.0--12.5V
11.5--12.0V
less than 11.50V
LOAD TEST
CAUTION: Remove the spark plug high tension lead
and connect securely to engine ground before
proceeding.
NOTE: This test cannot be performed with an engine
or starting system which is not working properly.
A battery may indicate a full charge condition in the OCV
test and the specific gravity test, but still may not have
the storage capacity necessary to properly function in
the electrical system. For this reason, a battery capacity
or load test should be conducted whenever poor battery
performance is suspected. To perform this test, hook a
multitester to the battery in the same manner as was
done in the OCV test. The reading should be 12.6 volts
or greater. Engage the electric starter and view the
registered battery voltage while cranking the engine.
Continue the test for 15 seconds. During this cranking
period, the observed voltage should not drop below 9.5
volts. If the beginning voltage is 12.6 or higher and the
cranking voltage drops below 9.5 volts during the test,
replace the battery.
5.5
ELECTRICAL
OFF SEASON STORAGE
To prevent battery damage during extended periods
of non-use, the following basic battery maintenance
items must be performed:
Remove the battery from the
machine and wash the case and
battery tray with solution of baking
soda and water. Rinse with lots of
fresh water after cleaning. NOTE:
Do not allow baking soda solution
into the battery or the acid will be
neutralized.
Using a wire brush or knife, remove
any corrosion from the cables and
terminals.
Charge at a rate no greater than 1/10
of the battery’s amp/hr capacity until
the battery reaches 12.8--13.0 volts.
Store the battery either in the
machine with the cables
disconnected, or put it on a piece of
wood and store in a cool place.
NOTE: Stored batteries lose their
charge at the rate of 1% per day.
They should be recharged to a full
charge every 30 to 60 days during a
non-use period. If the battery is
stored outside during the winter
months, the electrolyte will freeze at
a higher temperature as the battery
discharges. The chart below
indicates freezing points by specific
gravity.
Electrolyte Freezing Points
Specific Gravity
of Electrolyte
1.265 -75 F
1.225 -35 F
1.200 -17 F
1.150 +5 F
1.100 +18 F
1.050 +27 F
Freezing
Point
Routine Maintenance
Youth ATV Batteries
Check voltage periodically using a voltmeter
Check voltage every 3-- 6 months
depending on temperature. Higher temperatures cause faster discharge and require checking
more often.
Maintenance Free Batteries
should read 12.8--13.0v when
fully charged.
Keep the battery free of dirt and
grime.
Inspect the cables, clamps, and
fittings for damage or loose connections.
Clean terminals and connectors
as needed.
Pull battery or disconnect battery
cables during storage.
If a battery is stored, test regularly
and charge it if the voltage drops
below 12.5v.
If the vehicle is going to be stored
for an extended time, make sure
the battery is fully charged.
CHARGING PROCEDURE
Charge the battery with a charger no larger than 1/10
of the battery’s amp/hr rating. Youth ATV batteries
have an amp/hr rating of .4 volts. Do not exceed
this voltage or damage to the battery will result.
Fully charged, the battery should read 12.8-- 13.0
Volts. If the battery is 12.5--12.8 volts (75% capacity),
charge battery at 0.4 Amps for 3--6 hours. If the
voltage reads 12.0--12.5 Volts (50% capacity) charge
at 0.4 Amps for 5--11 hours. After charging is
complete, let the battery stand 1--2 hours and re--test
the voltage. Do not overcharge the battery!
After charging is complete, there is no need to remove
the cell cap strip or add water for the life of the battery.
Because of the characteristics of a sealed battery,
overcharging decreases the volume of electrolyte.
The longer the overcharge time, the greater the drop
in electrolyte, and subsequently starting power.
Water cannot be added to a sealed battery. If asealed
battery is overcharged, it will have to self--discharge
before it can be used. Overcharging can also warp
plates, making future charging difficult. Watch
5.6
charging times carefully, or use a charger with limited
charging time/current capabilities. Polaris
recommends using the Christie Multi--Battery
Charger PV-- 67030, available from our tool provider
SPX for charging batteries. Always stop charging if
the battery becomes warm to the touch. Let it cool
sufficiently before resuming charging.
When the charging system is complete, install the
battery in the ATV and connect the red positive (+)
cable first, and the black ground (--) cable last. Coat
battery bolt threads with corrosion resistant Nyogel
grease. Secure battery with the holder strap.
Nyogel Grease
(PN 2871329)
WARNING
To avoid the possibility of explosion, connect
positive (red) cable first and negative (black)
cable last.
ELECTRICAL
YOUTH ATV BATTERY CHARGING CHART
State
of
Charge
100% 12.8--13
75% 12.5--12
50% 12.0--12
25% 11.5 --12
0% 11.5v or
Vol tage Action Charge Time*
.0v
Charge
.8v
.5v
.0v
less
Charge
Charge 5--11 Hours @
Charge 13+Hours @ 0.4A
Charge 20 Hours @ 0.4A
* Charging times can vary depending on type
of charger. Follow the charger’s instructions.
None
Full
Slight
None Required
3-- 6 Hours @ 0.4A
0.4A
Check State
of Charge
Battery may
be Dead
5.7
ELECTRICAL
CHARGING SYSTEM TESTING
Whenever charging system problems are suspected,
proceed with the following system check.
Using a multitester set on D.C. volts, mea-
sure the battery open circuit voltage (See
Page 5.5). It should be 12.5 volts or more.
Is it?
Yes
Meter Setting: DC Volts
With the drive wheels securely off the ground,
start the engine and increase RPM to between
3000 and 4000. Read battery voltage with the
multitester. Readings should increase to be-
tween 13.0 and 14.6 V D.C. Are they?
No
No
Yes
Remove the battery and properly ser-
vice. Reinstall the fully charged battery
or a fully charged shop battery.
Check Key off Current Draw
Should between .1 and .2 volts
Meter Setting: DC Amps
Perform system “Break Even Amperage”
test outlined on Page 5.9.
Does charging occur as specified?
Ohm stator wire (W/YR) If bad replace, if good,
continue with alternator output test.
Meter Setting: AC Amps
Disconnect the Yellow/Red, White, and Red
wires from the regulator/rectifier. Using a
multitester, perform an Alternator Output
(AC amp) test. See test procedure on
page 5.9 for procedure.
Is output above 5 amps?
Meter Setting: DC Volts
Reconnect the alternator wires. Battery volt-
age must be present on red wire terminal on
harness side of voltage regulator connector.
No
Yes
Is it?
Yes
No
No
Check for owner modification, and
discuss operating habits. The battery
will continually discharge if operated
below the “Break Even” RPM. Con-
tinued problems would call for battery
inspection.
Inspect the wiring harness be-
tween the panel and the stator for
damage. If no damage is found,
remove the recoil and flywheel.
Inspect the flywheel magnets, sta-
tor coils and stator wire harness
for damage. Repair or replace
any damaged components.
Check regulator/rectifier connections
and ground, battery connections, cir-
cuit breaker and connecting wires.
Repair or replace faulty wiring or
components.
Yes
If all of the previous tests indicate a
good condition, but the charging voltage
does not rise above battery voltage at the
connector , replace the voltage regulator.
5.8
ELECTRICAL
CURRENT DRAW - KEY OFF
CAUTION: Do not connect or disconnect the
batterycableorammeterwiththeenginerunning.
Damage will occur to tail light bulb.
Connect an ammeter in series with the negative
battery cable. Check for current draw with the key off.
If the draw is excessive, loads should be
disconnected from the system one by one until the
draw is eliminated. Check component wiring as well
as the component for partial shorts to ground to
eliminate the draw.
Current Draw Inspection
Key Off
--+
Less Than 10 mA
Do not use electric start.
With engine off and the key and kill
switch in the ON position, the
ammeter should read negative amps
(battery discharge). Reverse meter
leads if a positive reading is
indicated.
Start engine with kick start only.
Increase engine RPM while
observing ammeter and tachometer.
Note RPM at which the battery starts
to charge (ammeter indication is
positive).
With any electrical load off, this
should occur at approximately 1500
RPMorlower.
Lock parking brake to keep brake
light on.
Repeat test, observing ammeter and
tachometer. With tailllight on,
charging should occur at or below
3000 RPM.
ALTERNATOR OUTPUT TEST
(AC AMPERAGE
TEST)
Current Draw - Key Off:
Maximum of .01 DCA (10 mA)
CHARGING SYSTEM “BREAK
EVEN”
CAUTION: Do not connect or disconnect the battery
cable or ammeter with the engine running.
CAUTION: Never use the electric starter with the
ammeter connected, or damage to the meter or meter
fuse may result. Do not run test for extended period
of time. Do not run test with high amperage
accessories.
The “break even” point of the charging system is the
point at which the alternator overcomes all system
loads (lights, etc.) and begins to charge the battery.
Depending on battery condition and system load, the
break even point may vary slightly. The battery should
be fully charged before performing this test.
TEST
Connect an ammeter (set to DC
amps) in series between the
negative battery cable and terminal.
Connect a tachometer according to
manufacturer’s instructions.
This test measures AC amperage from the alternator.
Maximum alternator output will be
indicated on the meter. It is not
necessary to increase engine
RPM above idle.
To Calculate Available Alternator Output:
P
=
E
P
=
E
P
=
E
I = Current in Amps
P=PowerinWatts
E = Electromotive Force (Volts)
Place the red lead on the tester in the
10A jack.
Turn the selector dial to the AC amps
) position.
(A
250W
12V
150W
12V
70W
12V
= 20.8 Amps
=
12.5 Amps
=
5.8 Amps
5.9
ELECTRICAL
Connect the meter leads to the
Yellow/Red and Black wires leading
from the alternator.
Start the engine using the kick
staRter and let it idle. Reading
should be a minimum of 3A at idle.
CAUTION: This testsimulatesa “fullload”onthe
alternator. Do not perform this test longer than
required to obtain a reading or the alternator
stator windings may overheat. 3-5 seconds is
acceptable. Do not rev the engine during thetest.
Alternator Current Output:
Minimum of 3 AC Amps
IGNITION
The ignition system has been upgraded for durability
by encapsulating the stator with an epoxy coating.
RPM speed limiting is now contained within the CDI
Module. Exhaust restrictors have been removed.
SPARK PLUG
Faulty starter button
Faulty ignition switch (Do other
systems function?)
Faulty starter solenoid or starter
motor.
Engine problem - seized or binding
(Can engine be rotated with kick
starter?)
Starter Motor Turns Over Slowly
Battery discharged
Excessive circuit resistance - poor
connections (see Voltage Drop Test
below)
Engine problem - seized or binding
(Can engine be rotated easily with
kick starter?)
Faulty or worn brushes in starter
motor
Starter Motor Turns - Engine Does Not Rotate
Faulty starter drive
Faulty starter drive gear or starter
motor gear
Faulty flywheel gear or loose
components
Spark Plug: NGK BPR7HS (PN 0450005)
STARTER SYSTEM
TROUBLESHOOTING
Starter Motor Does Not Turn
Battery discharged
Loose or faulty battery cables or
corroded connections (see Voltage
Drop Tests)
Related wiring loose, disconnected,
or corroded
Poor ground connections at battery
cable, starter motor or starter
solenoid (see Voltage Drop Tests)
Plug Gap
.024--.028”
(.6--.7mm)
VOLTAGE DROP TEST
The Voltage Drop Test is used to test for bad
connections. When performing the test, you are
testing the amount of voltage drop through the
connection. A poor or corroded connection will
appear as a high voltage reading. Voltage shown on
the meter when testing connections should not
exceed .1 VDC per connection or component
To perform the test, place the meter on DC volts and
place the meter leads across the connection to be
tested. Refer to the chart to perform voltage drop
tests on the starter system.
Voltage should not exceed
.1 DC volts per connection
.
5.10
ELECTRICAL
STARTER SYSTEM TROUBLESHOOTING
Condition: Starter fails to turn motor. NOTE: Make sure engine crankshaft is free to turn before proceeding with
dynamic testing of starter system. A digital multitester must be used for this test.
With the tester on the VDC position, place the tes-
ter’s black lead on the battery negative and the red
lead on the battery positive.
Reading should be 12.4 or greater.
Yes
No
Remove battery and properly service.
Install fully charged shop battery to continue
test.
Disconnect Red/White engagement coil wire from
the starter solenoid. Connect tester black wire to
battery ground. Connect red tester lead to Red/
White harness wire at solenoid. Turn on ignition
switch and depress the starter button. Tester
should read battery voltage.
Vol tage Drop Testing
Reconnect the solenoid. Connect the tester black
lead to the battery positive and the red lead to the
solenoid end of the battery-to-solenoid wire. De-
press starter button. Reading should be less than
Connect the black tester lead to solenoid end of
battery-to-solenoid cable. Connect red tester lead
to solenoid end of solenoid-to-starter cable. De-
press starter button. Reading should be less than
.1 V D.C.
.1 V D.C.
Yes
Yes
Check voltage on both sides of circuit
breaker, ignition switch/engine stop switch
and starter button. The voltage on both
sides should be the same. NOTE: The igni-
No
Test starter solenoid coil by connecting an ohmmeter between the solenoid
red wire and the solenoid mounting plate. Resistance should be 0
solenoid ground path by measuring resistance between mounting plate and
battery negative terminal (-).
No
No
tion switch and engine stop switch must be
on and the starter button depressed. Re-
place the defective component.
. Check
Clean the battery-to-solenoid cable ends or
replace the cable.
Replace the starter solenoid.
Yes
Connect the black tester lead to the solenoid end of
the solenoid-to-starter cable. Connect the red tester
lead to the starter end of the same cable. Depress
the starter button. The reading should be less than
.1 V D.C.
Yes
If all of these indicate a good condition, yet the starter still fails to turn, the
starter must be removed for static testing and inspection.
No
Clean the solenoid-to-starter cable ends or
replace the cable.
5.11
ELECTRICAL
STARTER MOTOR
DISASSEMBL
Bolt
Cord
NOTE: Use only electrical contact cleaner to clean
starter motor parts. Other solvents may leave a
residue or damage internal parts and insulation.
1. Disconnect the negative battery cable. Remove
the starter from the engine.
Y
Washer
Oil Ring
Brush Set
Oil Ring
Starter Bolts
3. Remove housing while holding the armature and
brush holder section together.
BRUSH INSPECTION/
REPLACEMENT
1. Using a digital multitester, measure the
resistance between the cable terminal and the
insulated brush. The reading should be .3 ohms
or less. Measure the resistance between the
cable terminal and brush housing. Make sure the
brush is not touching the case. The reading
should be infinite (no reading).
2. Remove the two bolts and washers.
Brush Set
Cord
2. Inspect the O Rings and replace if damaged.
5.12
ELECTRICAL
3. Remove brush plate and brushes. Measure
length of brushes and replace if worn past the
service limit.
Brush Length
Brush Length Service Limit:
5/16
4. Inspect surface of commutator for wear or
discoloration. See steps 3-6 of armature testing.
5. Install a new carbon brush assembly in the brush
housing. NOTE: Be sure that the terminal bolt
insulating washer is properly seated in the
housing, and the tab on the brush plate engages
the notch in the brush plate housing.
ARMATURE TESTING
1. Remove armature from starter casing. Note
order of shims on drive end for reassembly.
2. Inspect surface of commutator. Replace if
excessively worn or damaged.
3. Using a digital multitester, measure the
resistance between each of the commutator
segments. The reading should be .3 ohms or
less.
5/16”
(.8 cm)
4. Measure the resistance between each
commutator segment and the armature shaft.
The reading should be infinite (no continuity).
5. Check commutator bars for discoloration. Bars
discolored in pairs indicate shorted coils,
requiring replacement of the starter motor.
6. Place armature in a growler. Turn growler on and
position a hacksaw blade or feeler gauge
lengthwise 1/8
laminates. Rotate armature 360
blade is drawn to armature on any pole, the
armature is shorted and must be replaced.
7. Inspect permanent magnets in starter housing.
Make sure they are not cracked or separated from
housing.
CAUTION:
Use care when handling starter housing. Do not drop
or strike the housing as magnet damage is possible.
If magnets are damaged, starter must be replaced.
(.3 cm) above armature coil
. If hacksaw
STARTER REASSEMBLY
1. Place armature in field magnet casing.
2. Install case sealing O-Ring. Make sure O-Ring is
in good condition and not twisted on the case.
Lubricate the ends of the armature shaft and oil
seal with alight film of grease, and install housing.
3. Install O-Ring on the other end of field magnet
casing. Make sure it is in good condition and not
twisted on the case.
4. Install housing, pushing back brushes while
installing shaft in bushing.
5. Reinstall starter motor housing bolts. Make sure
O-Rings are in good condition and seated in
groove.
5.13
ELECTRICAL
Electronic Throttle Control
6. Reinstall the starter motor to the engine.
ELECTRONIC THROTTLE
CONTROL (ETC)
The Electronic Throttle Control (ETC) system is
designed to limit the engine RPM in the event of a
mechanical problem with the throttle mechanism.
The ETC switch is mounted independently of the
throttle actuator lever inside the throttle block
assembly. This is a normally open switch, and is held
in the closed position by throttle cable tension. In the
event of a mechanical problem in the throttle
mechanism (cable tension is lost), the switch contacts
open, connecting the CDI grey wire from ground,
limiting engine RPM to 1500.
SWITCH
Throttle is
Open
Throttle is
Closed
In the Event of
Cable Slack
Throttle Open
ETC Switch is
Closed. Connection from Grey to
Black.
ETC Switch Open.
NO connection
from Grey to
Black.
With cable slack
the ETC is open,
there is NO connection from grey
to black, the Engine RPM is limited to 1500 RPM.
Electronic Throttle Control (ETC) Switch
(Cast Aluminum Throttle
Housing)
A
Ill. 1
ETC Micro Switch
Button
5.14
Throttle Closed
ELECTRICAL
CRANKING TESTS
Unloaded Cranking Voltage
Wire Color Wire Description A/C Output
Yellow/Red to Black 3ProngPlug 4.5--5.9 Volts AC
WhitetoBlack 3ProngPlug 5.3--7.0 Volts AC
White/RedtoBlack Bullet Connector 0.3--0.4 Volts AC
Black/RedtoBlack Bullet Connector 90--120 Volts AC
Peak Reading Cranking Voltage
Wire Color (From Stator) Wire Description A/C Peak Output
(With Peak Reading Adapter and meter set to DCV scale)
Yellow/Red to Black 3ProngPlug 7.85 Volts DC
WhitetoBlack 3ProngPlug 9.50 Volts DC
White/RedtoBlack Bullet Connector 4.90 Volts DC
Black/RedtoBlack Bullet Connector 203 Volts DC
White/Red
Black/Red
3 Prong Plug
5.15
ELECTRICAL
COIL TESTING
Coil Primary Winding
Wire Description Resistance
Spade Connection
to Ground
Plug Cap (Cap Re-
sistance with Cap Removed)
Ignition Coil Secondary Winding
(Cap Removed)
Spade
0.5 -- 1.0 Ohms
4--5 K Ohms
5--9 K Ohms
Conntector Meter Reading
Yellow Red to
4.5--5 Volts AC
Black (Engine
Cranking)
Yellow Red to
7to9VoltsAC
Black (Engine
Running)
Black
Yellow/Red
IGNITION SYSTEM
TROUBLESHOOTING
No Spark, Weak or Intermittent Spark
Spark plug gap incorrect
Fouled spark plug
Faulty spark plug cap or poor
connection to high tension lead
Related wiring loose, disconnected,
shorted, or corroded
Engine Stop switch or ignition switch
faulty
ETC switch misadjusted or faulty
Poor ignition coil ground (e.g. coil
mount loose or corroded)
Faulty stator (measure resistance of
all ignition related windings)
Incorrect wiring (inspect color coding
in connectors etc)
Faulty ignition coil winding (measure
resistance of primary and secondary)
Worn magneto (RH) end Crankshaft
bearings
Sheared flywheel key
Flywheel loose or damaged
Excessive crankshaft runout on
magneto (RH) end should not exceed
.005
Faulty CDI module
5.16
ELECTRICAL
QUICK REFERENCE DIAGRAM
Scrambler 50/90, Predator 90 & Sportsman 90 Quick Reference Wire Diagram
Battery
RED
ETC Switch is OPEN the engine is
Main Switch
OnOff
NOTE: CDI BLK/WHT must have ground to run.
limited to 1500 RPM.
BRN
Low Oil
Switch
OR
Low Oil
Lamp
BLK
Brake
Switch
BLU/WHT
LH Engine Start Switch
LH Engine Cut off Switch
BRN (Splice)
GRN/Y
Solenoid
Off
Off
Start
On
BLK
On
Brake
Lamp
BLK
BLK/Y
NOTE: Connection closed in RUN position.
Connection open in OFF position.
CDI
Box
BLK/WHT
Off On
BLK/BLU
On Safety Switch
GRY
Main Key Switch
Off
ETC
Switch
(Engine)
BLK
NOTE: If the key does not
shut off the machine, th
wire on this circuit may b
grounded.
e
e
BLK
5.17
ELECTRICAL
SCRAMBLER 50 WIRING DIAGRAM
5.18
ELECTRICAL
SCRAMBLER 90 / SPORTSMAN 90 / PREDATOR 90 WIRING DIAGRAM
5.19
A
A--arm Mounting Bolt Torque, 4.4
Air Cleaner, 1.18
Air Screw, 3.6
Air Screw Adjustment, 1.13
Air Screw Adjustment Specifications, 1.13
Air/Fuel Mixture Ratio, 3.6
Alternator Output Test, 5.9
Axle Nut Torque, 4.8
B
Battery Charging, 5.6
Battery Charging Chart, 5.7
Battery Inspection/Removal, 5.5
Battery Installation, 5.5
Battery Load Test, 5.5
Battery Off Season Storage, 5.6
Battery Service, 5.4
Battery Terminals/Bolts, 5.4
Battery Testing, 5.5
Bearing Carrier Bolt Torque, 4.9
Bearing Housing Bolt Torque, 1.11
Belt Inspection, 2.16
Brake Lever Free Play, Front, 1.10, 4.12, 4.14
Brake Lever Free Play, Rear, 1.10, 4.12, 4.14
Brake Lever Travel, Front, 1.10, 4.12, 4.14
Brake Lever Travel, Rear, 1.10, 4.12, 4.14
Brake Light Bulb Replacement, 5.3
C
Cab Mounting Bolt Torque, 4.10, 4.11
Camber & Caster, 1.20
Carburetor Component Functions, 3.9
Carburetor Float Bowl Draining, 1.17, 3.11
Carburetor Float Height, 3.10
Carburetor Float Height Specification, 3.10
Carburetor Main System, 3.9
Carburetor Needle and Seat Testing, 3.10
Carburetor Operation, 3.4
Carburetor Specifications, 3.4
Carburetor System Function, 3.3
Carburetor Venting Systems, 3.10
Chain Adjuster Lock Nut Torque, 1.11
Chain Adjustment, 1.10
Chain Tension Spec, 1.10
Chain Tension Specification, 4.9
Chain Tensioner Nut Torque, 4.9
Charging System Break Even Test, 5.9
Charging System Testing, 5.8
Choke Adjustment, 1.14
Clutch Brake Lining Service Limit, 2.16
Clutch Cover Inner Diameter Service Limit, 2.16
Clutch Cover Inspection, 2.16
Coil and Enrichment Valve Tests, 5.16
Cold Weather Starting Procedures, 3.12
Compression Spring Inspection, 2.16
Compression Spring Service Limit, 2.16
Compression Test, 1.18
Connecting Rod Inspection, 2.13
Connecting Rod Small End Service Limit, 2.14
Conversion Table, 1.6
Crankcase Assembly, 2.18
Crankcase Bolt Torque, 2.18
Crankcase Cover Bolt Torque, 2.21
Crankcase Separating Tool, 2.9
Crankcase Separation, 2.9
Cranking and ETC Tests, 5.15
Crankshaft Alignment Fixture, 2.14
Crankshaft Removal Tool, 2.9
Crankshaft Runout, 2.14
Current Draw, 5.9
Cylinder Cleaning, 2.13
Cylinder Compression Specification, 1.18
Cylinder Head Inspection, 2.11
Cylinder Head Nut Torque, 2.21
Cylinder Head Warp, 2.11
Cylinder Honing, 2.12
Cylinder Inspection, 2.11
Cylinder Warp, 2.11
D
Decimal Equivalents, 1.7
Drive Belt Width Service Limit, 2.16
Drive Clutch Nut Torque, 2.17
Driven Clutch Nut Torque, 2.17
Driveshaft (Transmission) Assembly, 2.11
E
Electrical Service Notes, 5.2
Electronic Speed Control System, 1.9, 5.2
Engine Assembly, 2.18
Engine Disassembly, 2.4
Engine Inspection, 2.11
Engine Installation Notes, 2.4
Engine Mounting, 4.2, 4.3
Engine Removal, 2.3
Engine Torque Specifications, 2.2
ETC Switch Testing, 5.14
Fuel Line Maintenance, 1.16
Fuel System Warnings, 1.16
Fuel Tank Mounting Bolt Torque, 4.9
G
Glossary of Terms, 1.8
Grease Fitting Lubrication, 1.11
H
Handlebar Asm., Scrambler, 4.13
Handlebar Asm., Sportsman, 4.11
Handlebar Mounting Clamp Bolt Torque, 4.12,
4.14
Honing to Oversize, 2.13
I
Idle Speed Adjustment, 1.13
Idle Speed Specification, 1.13
Idler Gear Bolt Torque, 2.17
Inspection Schedule, 1.4
Intake Manifold Bolt Torque, 2.20
F
Fan Bolt Torque, 2.21
Float System, Carburetor, 3.5
Flywheel Nut Torque, 2.20
Flywheel Puller Tool, 2.6
Frame Photos, 4.2
Frame, Nuts, Bolts, Fasteners, 1.20
Front and Rear Cab, Scrambler, 4.10
Front and Rear Cab, Sportsman, 4.10
Front Brake Inspection, 1.10
Front Brake System, 4.6
Front Bumper Mounting Bolt Torque, 4.10, 4.11
Front Shock and Spring Inspection, 1.11
Fuel and Oil Tank, 4.9
Fuel Filter Maintenance, 1.16
J
Jet Needle, 3.6
Jet Needle/Needle Jet Effects, 3.8
Jetting Guidelines, 3.3
K
Kick Start and Spring Installation, 2.23
L
Lubricants, 1.5
M
Main Jet, 3.7
Model Identification, 1.2
Motor Mount Bolt Torque, 4.3
Muffler, 4.15
Muffler Mounting Bolt Torque, 4.15
Rear Brake Inspection, 1.10
Rear Shock and Spring Inspection, 1.11
Rear Shock Mounting Bolt Torque, 4.7
Reed Valve Air Gap Service Limit, 2.14
Reed Valve Inspection, 2.14
N
Needle Jet, 3.6
New for 2002 Models, 1.9, 5.2
O
Oil Pump Adjustment, 1.15
Oil Pump Bolt Torque, 2.19
Oil Pump Drive Gear Removal Tool, 2.7
Oil Pump Installation, 2.18
Oil Pump Troubleshooting, 1.16
Oil Tank Mounting Bolt Torque, 4.9
P
Paint Codes, 1.4
Pilot Jet, 3.5
Pilot System, 3.8
Piston Inspection, 2.12
Piston Installation, 2.20
Piston Pin Hole Inspection, 2.12
Piston Pin Hole Service Limit, 2.12
Piston Pin Inspection, 2.13
Piston Pin Service Limit, 2.13
Piston Ring Installed Gap, 2.12
Piston to Cylinder Clearance, 2.12
Pod Mounting Screw Torque, 4.13
Publication Numbers, 1.4
PVT System Assembly, 2.15
S
Serial Number Locations, 1.2
Shock Mounting Bolt Torque, 4.4
Shocks and Springs, Exploded View, 4.4
Slide Cutaway, 3.8
Spark Plug Recommendation, 5.10
Special Tools, 3.3
Special Tools, Electrical, 5.2
Special Tools, Engine, 2.2
Special Tools, Suspension, 1.5, 4.3
Specifications, General, 1.3
Specifications, Torque, Standard, 1.5
Specifications, Torque, Steering, 4.3
Speed Control Systems, 1.9, 5.2, 5.3
Spindle Nut Torque, 4.5, 4.7
Sprocket Bolt Torque, 4.8
Starter Armature Testing, 5.13
Starter Assembly, 5.13
Starter Brush Inspection/Replacement, 5.12
Starter Disassembly, 5.12
Starter System Test, 5.11
Starter Wheel Installation, 2.21
Stator Installation, 2.19
Stator Mounting Bolt Torque, 2.19
Stator Trigger/Flywheel Gap, 2.19
Steering Maintenance, 1.20
Steering Nut Torque, 4.6
Steering Post Nut Torque, 4.5
Steering System, 4.5
Suspension A--arms, Exploded View, 4.4
Swing Arm Mounting Bolt Torque, 4.7
R
Rear Brake and Axle, Exploded View, 4.7
T
Tap Drill Chart, 1.7
Throttle Cable Adjustment, 1.14
Throttle Opening vs. Fuel Flow, 3.7
Throttle Operation, 1.13
Throttle Stop Speed Control System, 1.9, 5.3
Throttle Valve, 3.7
Tie Rod Bolt Torque, 4.6
Tie Rod Jam Nut Torque, 4.6
Tire Inspection, 1.19
Tire Pressure, 1.19
Tire Tread Depth, 1.19
Toe Alignment, 1.21
Toe Alignment Adjustment, 1.21
Transmission Cover Bolt Torque, 2.11
Transmission Fluid Specifications, 1.12
Transmission Lubrication, 1.12
Troubleshooting, Engine, 2.25
Troubleshooting, Fuel System/Carb, 3.13
Troubleshooting, Ignition System, 5.16
Troubleshooting, Spark Plug, 2.25
Troubleshooting, Starter System, 5.10
V
Vechicle Inspection, 1.10
Vent Line Maintenance, 1.16
Voltage Drop Test, 5.10
Voltage Test Open Circuit, 5.5
VIN Identification, 1.2
W
Wheel, Hub, and Spindle Torque Table, 1.18
Wheel Inspection, 1.18
Wheel Installation, 1.19
Wheel Nut Inspection, 1.12
Wheel Nut Torque, 1.12
Wheel Removal, 1.18
Wiring Diagram, Quick Reference, 5.17
Wiring Diagram, Scrambler 50, 5.18
Wiring Diagram, Scrambler 90/Sportsman
90/Predator 90, 5.19
PN 9918068
Printed in USA
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