The ATV Polaris Predator 500 Workshop Repair Troubleshooting Manual (2003) is a comprehensive resource for maintaining and repairing the Polaris Predator 500 ATV model from 2003. It is an invaluable tool for both professional mechanics and DIY enthusiasts.
Chapter 1, General, provides detailed information about Model Identification, Serial Number Location, Publication Numbers, Replacement Keys, Standard Torque Specifications, Predator Models, Specifications, Tap Drill Charts, Decimal Equivalent Chart, Unit of Measure Conversion Table, and Glossary of Terms.
Chapter 2, Maintenance, outlines periodic maintenance, pre-ride inspection, lubrication and maintenance product numbers, special tools, clutch freeplay adjustment, throttle inspection, fuel system, compression test, spark plug and battery maintenance, electrical troubleshooting, coolant system maintenance, radiator screen removal, and air filter service.
Chapter 3, Engine/Transmission, explains torque specifications, service data, engine removal, cooling system pressure test, cooling system specifications, flow diagram, and cam timing diagram.
Chapter 4, Fuel System, contains an exploded view of the Mikuni BSR 42 carburetor, fuel tank assembly exploded view, fuel flow diagram, special tool & jetting guidelines, carburetor jetting, main jet / pilot jet part numbers, and float adjustment.
Chapter 5, Body/Suspension, includes body assembly and exploded view, steering assembly, front hub removal, front hub assembly/installation, steering knuckle removal/installation, ball joint removal/installation, and concentric swing arm removal.
Chapter 6, Brakes, provides detailed information about brake system service notes, brake noise troubleshooting, master cylinder removal/installation, and fluid replacement/bleeding procedure.
Chapter 7, Electrical System, covers timing check procedure, electrical switch testing, fan motor current draw test, electronic throttle circuit system operation, ignition system troubleshooting, and CDI output tests/stator output tests.
This manual is designed for use by certified Polaris Master Service Dealer technicians in a properly equipped shop, and it should be kept available for reference. Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop procedures in order to perform the work safely and correctly.
