Polaris ATV Predator 500 2003-2007 Online Manual
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Polaris Predator 500 (2003-2007)
Polaris Predator 500 (Troy Lee Designs) (2005-2006)
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Warnings, cautions and notes / Safety / Serial numbers / Fasteners / Shop supplies / Tools / Measuring tools / Electrical system fundamentals / Service methods / Storage / Specifications
CHAPTER TWO / TROUBLESHOOTING
Water damage / Starting the engine / Engine does not start / Poor engine performance / Electronic throttle control / Fuel system / Engine / Engine lubrication / Cylinder leakdown test / Clutch / Gearshift linkage / Transmission / Electrical testing / Front suspension and steering / Brake system / Specifications
CHAPTER THREE / LUBRICATION, MAINTENANCE AND TUNE-UP
Pre-ride inspection / Air box drain plugs / Air filter / Engine oil and filter change / Oil pressure test / Spark plug / Spark arrester cleaning / Fuel tank vent hose / Fuel hose inspection / Carburetor / Choke adjustment / Tune-up / Ignition timing / Valve clearance / Compression test / Control cables / Cooling system / Skid plate inspection / Specifications
CHAPTER FOUR / ENGINE TOP END
Engine service / Cylinder head cover / Camshaft / Camshaft chain tensioner / Camshaft chain, timing sprocket and chain guides / Cylinder head / Valve lifters and shims / Valves and valve components / Cylinder block / Piston and piston rings / Break-in procedure / Specifications
CHAPTER FIVE / ENGINE LOWER END
Engine removal and installation / Crankcase / Water pump mechanical seal and bearing replacement / Crankshaft / Balancer shaft inspection / Primary drive gear / Oil pump / One-way check valve / Oil tank, oil pipe and hoses / Break-in procedure / Specifications
CHAPTER SIX / CLUTCH AND EXTERNAL SHIFT MECHANISM
Right crankcase cover / Clutch / Cable / External shift mechanism / Specifications
CHAPTER SEVEN / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM (2003-2004 MODELS)
Transmission and internal shift mechanism / Transmission inspection / Specifications
CHAPTER EIGHT / TRANSMISSION AND INTERNAL GEARSHIFT MECHANISM (2005-ON MODELS)
Transmission and internal shift mechanism / Transmission inspection / Internal shift mechanism inspection / Reverse gear arm shifter / Specifications
CHAPTER NINE / FUEL AND EXHAUST SYSTEMS
Carburetor / Pilot screw / Carburetor tests and adjustments / Throttle cable / Choke cable / Fuel tank / Fuel shutoff valve / Air box / Fuel pump / Exhaust system muffler spark arrester / Specifications
CHAPTER TEN / ELECTRICAL SYSTEM
Electrical connectors / Battery / Charging system / Voltage regulator rectifier / Capacitor discharge ignition CDI / Alternator cover and stator coil / Alternator rotor and starter gears / Ignition coil / Starter / Starter solenoid / Lighting system / Switches / Cooling system fan switch and sensor / Circuit breaker / Specifications
CHAPTER ELEVEN/ COOLING SYSTEM
Coolant reservoir / Radiator / Cooling fan / Water pump / Thermostat / Cooling fan switch / Engine coolant temperature sensor / Specifications
CHAPTER TWELVE / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Shock absorber / Tie rods / Front spindle / Control arms / Center link and idle arm (2003-2006 models) / Handlebar / Steering shaft / Tires and wheels / Specifications
CHAPTER THIRTEEN / REAR SUSPENSION
Rear wheel / Rear hub / Rear axle / Rear axle eccentric / Drive chain / Sprockets / Shock absorber / Swing arm / Specifications
CHAPTER FOURTEEN / BRAKES
Brake service / Front brake pad replacement / Front caliper (2003-2006 models) / Front caliper (2007 models) / Front master cylinder / Rear brake pad replacment / Rear caliper (2003-2006 models) / Rear caliper (2007 models) / Rear master cylinder / Brake hose replacement / Rear brake pedal / Brake disc / Brake bleeding / Specifications
CHAPTER FIFTEEN / BODY
Side panels / Front fender / Rear fender / Heel pocket and mounting bracket / Specifications
INDEX
COLOR WIRING DIAGRAMS
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- All colour step-by-step guides for over 200 jobs with 700+ photos
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- Troubleshooting section – quickly find the cause of a problem
- Colour wiring diagrams help track problems quickly and easily
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- Dictionary of automotive terms
- Quick links to popular DIY tasks and other jobs linked to your task
- Conversion calculator – imperial and metric units
