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Polaris Scrambler 5090 Sportsman 90 Service Manual - PDF

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF

Name: Polaris Scrambler 5090 Sportsman 90 Service Manual - PDF
SKU: 963664
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Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

Category: Polaris Tags: Polaris Scrambler 5090 Sportsman 90, Polaris Scrambler 5090 Sportsman 90 Service Manual, Polaris Scrambler 5090 Sportsman 90 Service Manual - PDF DOWNLOAD Vendor: Chassis Manuals

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Description

Description

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

FILE DETAILS:

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

Language : English
Pages : 125
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

Model Identification11
Serial Number Location11
Specifications – General12
Publication Numbers 13
Paint Codes13
Standard Torque Specifications14
Lubricant and Maintenance Part Numbers14
Torque Conversion Table 15-16
Decimal Equivalent Chart 17
Unit of Measure Conversion Table 18
Tap Drill Charts19
Glossary of Terms 110-111
Inspection Schedule 112
Vehicle Inspection 113-115
Transmission Lubrication 116
Throttle Operation / Air Screw Adjustment117
Idle Speed Adjustment 118
Throttle Cable Adjustment118-119
Oil Pump Adjustment / Bleeding 120
Oil Pump Troubleshooting121
Fuel System122-123
Compression Test 124
Air Filter Service 124
Wheels and Tires125-126
Alignment127-128
CHAPTER 2
ENGINE
Torque Specifications 21
Special Tools, Engine 21
Engine Installation Notes22
Engine Disassembly23-212
Engine Inspection213-215
Cylinder Honing216
Crankshaft Runout Inspection217
Engine Assembly 218-216
Spark Plug Fouling 227
Engine Troubleshooting 228-229
CHAPTER 3
FUEL SYSTEM/CARBURETION
Fuel System Warnings 31
Carburetor Operation32
Float System32
Pilot Jet / Pilot Air Screw / Air/Fuel Mixture33
Jet Needle / Needle Jet / Throttle Opening34
Throttle Valve / Main Jet35
Pilot System36
Slide Cutaway / 1/8-3/8 Throttle 37
Jet Needle / Needle Jet / 3/8-3/4 Throttle 38
Main System / 3/4 to Full Throttle39
Fuel Delivery310
Vent Systems / Float Height 311
Needle and Seat Leakage Test311
Carburetor Float Bowl Draining312
Carburetor Exploded View313
Troubleshooting 314-315
CHAPTER 4
BODY AND STEERING
Torque Specifications and Special Tools 41
Frame Photos42
Engine Mounting 43-44
Shocks and Springs 45
Suspension A-arms 46
Steering 47-48
Front Brake49-410
Rear Brake and Axle410-413
Fuel and Oil Tank 414
Front and Rear Cab 415
Handlebar 416-418
Muffler418
CHAPTER 5
ELECTRICAL
Special Tools 51
Electrical Service Notes 51
Brakelight Lamp Replacement51
Battery Service / Terminals and Bolts52
Battery Inspection / Removal 53
Battery Installation / Testing53
Open Circuit Voltage Test53
Specific Gravity Test / Load Test54
Off Season Storage / Charging Procedure 55
Electronic Parts / Current Draw-Key Off 56
Charging System Testing57
Ignition System 58-59
Cranking Output Test510
CDI Output Test510
Charging System Testing511-512
Alternator Output Test (AC Amp)513
Starter System Troubleshooting / Voltage Drop Test 514
Starter System 515
Starter Motor Disassembly 516-517
Brush Inspection / Replacement517-518
Armature Testing 518
Starter Assembly 519
Electronic Throttle Control (ETC) 520
Ignition System Troubleshooting521
Wiring Diagram – Scrambler 50 522
Wiring Diagram – Scrambler 90 / Sportsman 90 523

DESCRIPTION:

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

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: Keep away from moving fan.

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.

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

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

G.B 05/04/25

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

Description

Polaris Scrambler 5090 Sportsman 90 Service Manual – PDF DOWNLOAD

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