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2003 - 2007 Polaris Predator 500 Clymer ATV Maintenance, Troubleshooting, Repair Manual
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This new Clymer Repair Manual is for the Polaris Predator spanning 2003-2007.
Coverage:
- Predator 500 (2003-2007)
- Predator 500 - Troy Lee Designs (2005-2006)
Like all Clymer ATV repair manuals, this book also contains:
- Step-by-step instructions
- Detailed and exploded views and photos
- Bold figure numbers to quickly match instructions with illustrations and photos
- Easy-to-follow wiring diagrams
- Thumb-tabbed chapters for quick access
- Two-column layout with large print
- Numbered table of contents and extensive index
Clymer manuals provide step-by-step procedures based on the complete disassembly of the machine. This hands-on experience combined with extensive research results in a manual that is both detailed and user friendly. Accurate, clear and concise text, combined with detailed illustrations and photography, make it possible for the novice ATV enthusiast to safely and enjoyably service their vehicle. At the same time, the in-depth coverage provides indispensable information for those tackling more complicated procedures.
Table of Contents:
This Polaris Predator manual is 352 pages.
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
Models covered:
2003 2004 2005 2006 2007 Polaris Predator 500
2005 2006 Polaris Predator 500 (Troy Lee Designs)
This Polaris Predator manual is 352 pages.
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
Models covered:
2003 2004 2005 2006 2007 Polaris Predator 500
2005 2006 Polaris Predator 500 (Troy Lee Designs)
| Specifications | |
| Publisher: | Clymer |
| Paperback: | 333 pages |
| Dimensions: | 10.0 x 7.0 x 0.5 inches |
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