2001 Polaris Scrambler 50/90, Sportsman 90 Service Manual


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 High definition, bookmarked, searchable, printable PDF  Instant download

Covers: 2001 Polaris Scrambler 50 & 90, Sportsman 90 ATV
Pages: 125
Format: PDF
Compatibility: Windows/Mac/Tablet

This downloadable service manual contains instructions and technical information to maintain and repair your 2001 Polaris Scrambler 50/90 or Sportsman 90 ATV. This is the same manual technicians use to diagnose and repair your ATV. Whether it’s routine maintenance, such as tune-ups and brake service, or more extensive repairs involving engine and transmission disassembly, the service manual provides the most accurate information to perform the job. The bookmarks panel in this manual makes it easy to quickly navigate chapters and sub-chapters.


Model Identification
Serial Number Location
Specifications – General
Publication Numbers
Paint Codes
Standard Torque Specifications
Lubricant and Maintenance Part Numbers
Torque Conversion Table
Decimal Equivalent Chart
Unit of Measure Conversion Table
Tap Drill Charts
Glossary of Terms
Inspection Schedule
Vehicle Inspection
Transmission Lubrication
Throttle Operation / Air Screw Adjustment
Idle Speed Adjustment
Throttle Cable Adjustment
Oil Pump Adjustment / Bleeding
Oil Pump Troubleshooting
Fuel System
Compression Test
Air Filter Service
Wheels and Tires

Torque Specifications
Special Tools, Engine
Engine Installation Notes
Engine Disassembly
Engine Inspection
Cylinder Honing
Crankshaft Runout Inspection
Engine Assembly
Spark Plug Fouling
Engine Troubleshooting

Fuel System Warnings
Carburetor Operation
Float System
Pilot Jet / Pilot Air Screw / Air/Fuel Mixture
Jet Needle / Needle Jet / Throttle Opening
Throttle Valve / Main Jet
Pilot System
Slide Cutaway / 1/8-3/8 Throttle
Jet Needle / Needle Jet / 3/8-3/4 Throttle
Main System / 3/4 to Full Throttle
Fuel Delivery 0
Vent Systems / Float Height
Needle and Seat Leakage Test
Carburetor Float Bowl Draining
Carburetor Exploded View

Torque Specifications and Special Tools
Frame Photo
Engine Mounting
Shocks and Springs
Suspension A-arms
Front Brake
Rear Brake and Axle
Fuel and Oil Tank
Front and Rear Cab

Special Tools
Electrical Service Notes
Brakelight Lamp Replacement
Battery Service / Terminals and Bolts .
Battery Inspection / Removal
Battery Installation / Testing
Open Circuit Voltage Test
Specific Gravity Test / Load Test
Off Season Storage / Charging Procedure
Electronic Parts / Current Draw-Key Off
Charging System Testing
Ignition System
Cranking Output Test
CDI Output Test
Charging System Testing
Alternator Output Test (AC Amp)
Starter System Troubleshooting / Voltage Drop Test
Starter System
Starter Motor Disassembly
Brush Inspection / Replacement
Armature Testing
Starter Assembly
Electronic Throttle Control (ETC)
Ignition System Troubleshooting
Wiring Diagram – Scrambler 50
Wiring Diagram – Scrambler 90 / Sportsman 90


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