2003-2007 Polaris Predator 500 & Troy Lee Limited Edition Predator 500 ATV Service Repair Manual

CHAPTER INDEX CHAPTER 1 GENERAL CHAPTER 2 MAINTENANCE CHAPTER 3 ENGINE/TRANSMISSION CHAPTER 4 FUEL SYSTEM CHAPTER 5 BODY/SUSPENSION CHAPTER 6 BRAKES CHAPTER 7 ELECTRICAL

1 GENERAL INFORMATION 1.1 CHAPTER 1 GENERAL INFORMA TION Model Identification 1.2 ....................... Serial Number Location 1.2 ................... Publication Numbers 1.3 ..................... Replacement Keys 1.3 ....................... Standard Torque Specifications 1.3 ............ Predator Models 1.4 ......................... Specifications 1.5-1.6 ............................ Tap Drill Charts 1.7 .......................... Decimal Equivalent Chart 1.7 ................. Unit of Measure Conversion Table 1.8 .......... Glossary of Terms 1.9 ........................

GENERAL INFORMATION 1.2 MODEL IDENTIFICA TION The machine model number must be used with any correspondence regarding warranty or service. Machine Model Number Identification YearDesignation Basic Chassis Designation Engine Designation A 03 GJ 50 AA Emissions & Model Option ENGINE DESIGNATION NUMBER ES50PLE01 Single,WaterCooled,ElectricStart,Manual5--Speed,DOHC4Stroke ................ VIN IDENTIFICA TION 1 2 3 4 5 6 7 8 9 10 1 1 12 13 14 15 16 17 4XAGA50A*3P000000 Vehicle Descriptor Vehicle Identifier Powertrain Engine Emissions Model Year Plant No.* Individual Serial No. Body Style Check Digit* World Mfg. ID * This could be either a number or a letter UNIT MODEL NUMBER AND SERIAL NUMBER LOCA TION Whenever corresponding with Polaris about a particular issue, the machine model number and serial number are important for vehicle identification. The machine serial number is stamped on the lower left side of the frame tube.(B) ENGINE SERIAL NUMBER LOCA TION This information can be found on the clutch housing on the left side of engine.(A) A RH View B LH View

31XX Key Series Number GENERAL INFORMATION 1.3 PUBLICATION NUMBERS Year Model Model No. Owner’s Manual PN Parts Manual PN Parts Micro Fiche PN 2003 PREDATOR A03GJ50CA 9917574 9917576 9917577 2003 PREDATOR A03GJ50CA 9917574 9917576 9917577 NOTE: When ordering service parts be sure to use the correct parts manual. REPLACEMENT KEYS Replacement keys can be made from the original key. To identify which series the key is, take the first two digits on the original key and refer to the chart to the right for the proper part number. Should both keys become lost, replacement of the ignition switch assembly is necessary. Series # Part Number 20 4010278 21 4010278 22 4010321 23 4010321 27 4010321 28 4010321 31 4110141 32 4110148 67 4010278 68 4010278 STANDARD TORQUE SPECIFICA TIONS The following torque specifications are to be used as a general guideline. FOR SPECIFIC TORQUE VALUES OF FASTENERS Refer to exploded views in the appropriate section. There are exceptions in the steering, suspension, and engine sections. Bolt Size Threads/In Grade 2 Grade 5 Grade 8 Torque in. lbs. (Nm) #10 - 24 27 (3.1) 43 (5.0) 60 (6.9) .............. ................ .............. #10 - 32 31 (3.6) 49 (5.6) 68 (7.8) .............. ................ .............. Torque ft. lbs. (Nm) * 1/4 - 20 5 (7) 8 (11) 12 (16) .............. .................. ................ 1/4 - 28 6 (8) 10 (14) 14 (19) .............. .................. .............. 5/16 - 18 11 (15) 17 (23) 25 (35) .............. ................ .............. 5/16 - 24 12 (16) 19 (26) 29 (40) .............. ................ .............. 3/8 - 16 20 (27) 30 (40) 45 (62) .............. ................ .............. 3/8 - 24 23 (32) 35 (48) 50 (69) .............. ................ .............. 7/16 - 14 30 (40) 50 (69) 70 (97) .............. ................ .............. 7/16 - 20 35 (48) 55 (76) 80 (110) .............. ................ .............. 1/2 - 13 50 (69) 75 (104) 110 (152) .............. ................ ............. 1/2 - 20 55 (76) 90 (124) 120 (166) .............. ................ ............. Metric / Torque 6 x 1.0. 72-78 In. lbs. 8 x 1.25 14-18 ft. lbs 10 x 1.25 26-30 ft. lbs.

GENERAL INFORMATION 1.4 PREDATOR MODELS PREDATOR 500 PREDATOR 500 TROY LEE LIMITED EDITION

GENERAL INFORMATION 1.5 MODEL: 2003 PREDATOR 500 .......... MODEL NUMBER: A03GJ50AA . ENGINE MODEL: ES50PLX .. Catagory Dimension Length 71.5 in./182 cm Width 47.5 in./121 cm Height 45 in./114 cm Seat Height 32 in./81.28 cm Wheel Base 51 in./130 cm Ground Clearance 4.5 in./11 cm Dry Weight 415 lbs./188 kg Fuel Capacity 3.25 gal./12.3 ltr Oil Capacity 2.25 qts./2.1 ltr Coolant Capacity 2.25 qts./2.1 ltr Dune Package Shown

GENERAL INFORMATION 1.6 MODEL: 2003 PREDATOR 500 .......... MODEL NUMBER: A03GJ50AA . ENGINE MODEL: ES50PLE01 .. Engine Platform Fuji DOHC 4 stroke Engine Model Number ES50PLE01 Engine Displacement 499cc Number of Cylinders 1 Bore & Stroke (mm) 99.2 x 64.6 mm Compression Ratio 10.8:1 Compression Pressure 130 psi Engine Idle Speed 1600 Rpm Cooling System Liquid Thermostat Opening Temperature 160 F (71 C) Overheat Warning High Temp Light Lubrication Pressurized Dry Sump Oil Requirements PS--4 Synthetic Exhaust System 2 to 1 canister style Carburetion Carburetor model Mikuni BSR 42mm Main Jet 150 Pilot jet 45 Jet Needle 6CGY07-060-3 Needle Jet O-OM Pilot Screw 2.5 Turns Out Pilot Air Jet 110 Float Height 13--14 mm (0.51--0.55“) Fuel Delivery Fuel Pump Fuel Requirement 87 Octane (minimum) Electrical Alternator Output 200 w @ 3000 RPM Voltage Regulator 3--Phase PN 4010654 Lghts : Main Headlights Dual Beam 35 watts / 35 watts Tail 8.26 watts Brake 26.9 watts Neutral / Hot Indicator lights 1 watt (ea.) Ignition System DC/CDI Ignition RPM Limit 9005 Ignition Timing 30 3 BTDC @ 3500 RPM Spark plug / Gap NGK DCPR8E/ .035 in./ 0.9 mm Battery / Model / Amp Hr Maintenance--Free Yuasa YTX9 9 Amp Hr Circuit Breakers Fan 10 amp / Harness 20 amp Starting Electric -- Standard Instrument Cluster N/A Drivetrain Transmission Type Manual 5 speed Main Sprocket -- # Tooth 14 Rear Sprocket -- #Tooth 37 Axle Runout -- Maximum .020” (.51 mm) Gear Ratio : 1st 2nd 3rd 4th 5th Primary 2.615 1.765 1.350 1.091 0.958 2.792 Chain Size / Deflection 520 O--ring Clutch Type Wet Multi Plate Clutch Lever Freeplay 1/8 - 3/16 / 3.1 - 4.7 mm Steering / Suspension Front Suspension Style / Shock Dual A--arm / Fox Shock Front Travel 10 in. / 25.4 cm Rear Suspension Style / Shock Linkless Swing Arm / Fox Shock w/ remote reservoir Rear Travel 11 in. / 27.94 cm Ground Clearance 4.5 in. / 11.43 cm Shock Preload Adjustment Front / Rear Front -- Springtension -- Std. Rear -- Fox DualClicker -- Std. Turning Radius 67 in. / 170.18 cm Toe Out 0 -- 1/16in/ .0 -- .159cm Wheels / Brakes Wheel Size -- Front 21x7--10 Aluminum Wheel Size -- Rear 20x11--10 Aluminum Front Tire Make / Model / Size Maxxis Razr 21x7--10 Rear Tire Make / Model / Size Maxxis Razr 20x11--10 Recommended Air Pressure F/R 5 psi Front 5 psi Rear Brake -- Front Dual Hydraulic Disc Brake -- Rear Single Hydraulic Disc JETTING CHART Altitude Meters (Feet) AMBIENT TEMPERATURE 0--1800 (0--6000) above 1800 (above 6000) Below 40 F Below 5 C +40 F to +80 F +5 C to +28 C 155 150 147.5 142.5

GENERAL INFORMATION 1.7 SAE TAP DRILL SIZES Thread Size/Drill Size Thread Size/Drill Size #0-80 3/64 #1-64 53 #1-72 53 #2-56 51 #2-64 50 #3-48 5/64 #3-56 45 #4-40 43 #4-48 42 #5-40 38 #5-44 37 #6-32 36 #6-40 33 #8-32 29 #8-36 29 #10-24 24 #10-32 21 #12-24 17 #12-28 4.6mm 1/4-20 7 1/4-28 3 5/16-18 F 5/16-24 I 3/8-16 O 3/8-24 Q 7/16-14 U 7/16-20 25/64 1/2-13 27/64 1/2-20 29/64 9/16-12 31/64 9/16-18 33/64 5/8-11 17/32 5/8-18 37/64 3/4-10 21/32 3/4-16 11/16 7/8-9 49/64 7/8-14 13/16 1-8 7/8 1-12 59/64 1 1/8-7 63/64 1 1/8-12 1 3/64 1 1/4-7 1 7/64 1 1/4-12 1 11/64 1 1/2-6 1 11/32 1 1/2-12 1 27/64 1 3/4-5 1 9/16 1 3/4-12 1 43/64 2-4 1/2 1 25/32 2-12 1 59/64 2 1/4-4 1/2 2 1/32 2 1/2-4 2 1/4 2 3/4-4 2 1/2 3-4 2 3/4 METRIC TAP DRILL SIZES Tap Size Drill Size Decimal Equivalent Nearest Fraction 3x.50 3x.60 4x.70 4x.75 5x.80 5x.90 6 x 1.00 7 x 1.00 8 x 1.00 8 x 1.25 9 x 1.00 9 x 1.25 10 x 1.25 10 x 1.50 11 x 1.50 12 x 1.50 12 x 1.75 #39 3/32 #30 1/8 #19 #20 #9 16/64 J 17/64 5/16 5/16 11/32 R 3/8 13/32 13/32 0.0995 0.0937 0.1285 0.125 0.166 0.161 0.196 0.234 0.277 0.265 0.3125 0.3125 0.3437 0.339 0.375 0.406 0.406 3/32 3/32 1/8 1/8 11/64 5/32 13/64 15/64 9/32 17/64 5/16 5/16 11/32 11/32 3/8 13/32 13/32 DECIMAL EQUIV ALENTS 1/64 .0156 ................ 1/32 .0312 1 mm = .0394 ........... ... 3/64 .0469 ................ 1/16 .0625 ........... 5/64 .0781 2 mm = .0787 ................ ... 3/32 .0938 ........... 7/64 .1094 3 mm = .1181 .............. ... 1/8. .1250 ... 9/64 .1406 ................ 5/32 .1563 4 mm = .1575 ........... ... 11/64 .1719 ............... 3/16 .1875 5 mm = .1969 ........... ... 13/64 .2031 ............... 7/32 .2188 ........... 15/64 .2344 6 mm = .2362 ............... ... 1/4 .25 .... 17/64 .2656 7 mm = .2756 ............... ... 9/32 .2813 ........... 19/64 .2969 ............... 5/16 .3125 8 mm = .3150 ........... ... 21/64 .3281 ............... 11/32 .3438 9 mm = .3543 .......... ... 23/64 .3594 ............... 3/8 .375 .... 25/64 .3906 10 mm = .3937 ............... ... 13/32 .4063 ......... 27/64 .4219 11 mm = .4331 ............... ... 7/16 .4375 ........... 29/64 .4531 ............... 15/32 .4688 12 mm = .4724 ......... ... 31/64 .4844 ............... 1/2 .5 13 mm = .5118 .... .............. 33/64 .5156 ............... 17/32 .5313 ......... 35/64 .5469 14 mm = .5512 ............... ... 9/16 .5625 ........... 37/64 .5781 15 mm = .5906 ............... ... 19/32 .5938 ......... 39/64 .6094 ............... 5/8 .625 16 mm = .6299 .... ............ 41/64 .6406 ............... 21/32 .6563 17 mm = .6693 ......... ... 43/64 .6719 .............. 11/16 .6875 .......... 45/64 .7031 18 mm = .7087 ............... ... 23/32 .7188 ......... 47/64 .7344 19 mm = .7480 ............... ... 3/4 .75 .... 49/64 .7656 ............... 25/32 .7813 20 mm = .7874 ......... ... 51/64 .7969 ............... 13/16 .8125 21 mm = .8268 ......... ... 53/64 .8281 ............... 27/32 .8438 ......... 55/64 .8594 22 mm = .8661 ............... ... 7/8 .875 .... 57/64 .8906 23 mm = .9055 ............... ... 29/32 .9063 ......... 59/64 .9219 .............. 15/16 .9375 24 mm = .9449 ......... ... 61/64 .9531 ............... 31/32 .9688 25 mm = .9843 ......... ... 63/64 .9844 ............... 1 1.0 .....

GENERAL INFORMATION 1.8 CONVERSION T ABLE Unit of Measure Multiplied by Converts to ft. lbs. x12 = in. lbs. in. lbs. x .0833 = ft. lbs. ft. lbs. x 1.356 = Nm in. lbs. x .0115 = kg-m Nm x .7376 = ft. lbs. kg-m x 7.233 = ft. lbs. kg-m x 86.796 = in. lbs. kg-m x 9.807 = Nm in. x 25.4 =mm mm x .03937 = in. in. x 2.54 =cm mile (mi.) x 1.6 =km km x .6214 = mile (mi.) Ounces (oz) x 28.35 = Grams (g) Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc) Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.) Grams (g) x 0.035 = Ounces (oz) lb. x .454 =kg kg x 2.2046 = lb. Cubic inches (cu in) x 16.387 = Cubic centimeters (cc) Cubic centimeters (cc) x 0.061 = Cubic inches (cu in) Imperial pints (Imp pt) x 0.568 = Liters (l) Liters (l) x 1.76 = Imperial pints (Imp pt) Imperial quarts (Imp qt) x 1.137 = Liters (l) Liters (l) x 0.88 = Imperial quarts (Imp qt) Imperial quarts (Imp qt) x 1.201 = US quarts (US qt) US quarts (US qt) x 0.833 = Imperial quarts (Imp qt) US quarts (US qt) x 0.946 = Liters (l) Liters (l) x 1.057 = US quarts (US qt) US gallons (US gal) x 3.785 =Liters (l) Liters (l) x 0.264 = US gallons (US gal) Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa) Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi) Kilopascals (kPa) x 0.01 = Kilograms - force per square cm Kilograms - force per square cm x 98.1 = Kilopascals (kPa) xR 2 x H (height) = Cylinder Volume CtoF:9(C+40) 5-40=F FtoC:5(F+40) 9-40=C

2003-2007 Polaris Predator 500 & Troy Lee Limited Edition Predator 500 ATV Service Repair Manual

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