2005 Polaris Predator 500 Parts Manual
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PARTS MANUAL PN 9919511 and MICROFICHE PN 9919512 7/04
PREDATOR 500
Model #A05GJ50AA
PREDATOR 500 TROY LEE
Model #A05GJ50AB
TABLE OF CONTENTS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
Parts Manual
A
AIR BOX D2 ...........................
AIR INTAKE B13 .........................
AXLE, REAR B7 ........................
B
BRAKE, FRONT B11 .....................
BRAKE, REAR B9 ......................
C
CAB, FRONT A5 ........................
CAB, REAR A4 .........................
CALIPERS, FRONT B10 ...................
CALIPERS, REAR B10 ....................
CARBURETOR C9-10 .......................
CHAIN COVER D8 .......................
CLUTCH D5-7 ...........................
CLUTCH LEVER A10 .....................
CONTROLS A9 .........................
COOLING A11 ..........................
CRANKCASE C5 ........................
CRANKSHAFT D1 .......................
CYLINDER C6 ..........................
D
DECALS (AA) A7 ........................
DECALS (AB) A8 ........................
E
ELECTRICAL B14 ........................
ENGINE MOUNTING A13 ..................
EXHAUST C7-8 ..........................
EXHAUST SYSTEM A12 ...................
F
FRAME, MAIN A3 .......................
FUEL PUMP D4 .........................
FUEL TANK B1 .........................
H
HEADLAMPS A6 ........................
HOUSING B7 ..........................
HUB, FRONT B5 .......................
I
INTAKE C7-8 ............................
M
MAGNETO C14 ..........................
MASTER CYLINDER, FRONT BRAKE B12 .....
O
OIL FILTER C13 .........................
OIL PUMP C12 ..........................
OIL TANK A14 ...........................
P
PISTON D1 ............................
S
SEAT A4 ..............................
SHOCK, FRONT C1 ......................
SHOCK, FRONT C2 .....................
SHOCK, REAR C3 ......................
SHOCK, REAR, RESERVOIR MOUNTING C4 ...
SIDE PANELS A5 .......................
STARTING MOTOR D3 ...................
STEERING B2-3 ..........................
SUSPENSION, FRONT B4 ................
SWING ARM B8 ........................
T
TOOL KIT D9 ...........................
W
WATER PUMP C11 .......................
WHEEL, FRONT B5 .....................
WHEEL, REAR B6 ......................
The illustrations used in this Parts Manual are for reference to replacement parts only. This manual is not to be used for assembly.
A3
MAIN FRAME
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
3
14
15
8
7
9
12
11
10
13
16
8
2
2
6
5
4
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 1013995-385 1 Bar, Grab, Silver
2 7515399 8 Screw
3 1014799-385 1 Frame, Rear, Silver
4 7556042 2 Washer
5 7517857 2 Screw
6 5412067 2 Bumper, Rubber
7 1013851-385
1013851-067
1
1
Peg, Foot, LH, Silver (AA)
Peg, Foot, LH, Black (AB)
8 7517632 4 Screw
9 1013774-385 1 Bumper, Front, Silver
10 7517386 5 Screw
11 7555859 5 Washer, Flat
12 5435737 1 Guard, Rock
13 1014780-385 1 Frame, Main, Silver
14 7542343 2 Nut, Flange
15 1013852-385 1 Peg, Foot, RH, Silver
16 7515307 2 Screw
7/04
A4
REAR CAB and SEAT
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
17
19
20
18
15
16
4
3
11
9
6
5
8
2
7
10
14
11
9
9
7
10
9
10
13
10
2
12
10
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 2683687-070
2683686-070
2683655
2683656
1
1
1
1
Asm., Seat (AA)
Covering, Seat (AA)
Asm., Seat (AB)
Asm., Cover (AB)
2 7518196 6 Screw
3 5412507 2 Grommet
4 5435231-293
5435231-496
1
1
Cab, Rear, Indy Red (AA)
Cab, Rear, Cosmic Sun (AB)
5 7515199 4 Screw
6 7541925 2 Nut, Nylok
7 7555792 6 Washer
8 1014438-385
1014439-385
1
1
Support, Rear Cab, LH, Silver
Support, Rear Cab, RH, Silver
9 7542153 12 Nut, Nylok, Flange
10 7512297 20 Screw
11 5434432-070
5434433-070
1
1
Pocket, Heel, LH, Black
Pocket, Heel, RH, Black
12 7552801 4 Washer, Spring Lock
13 1014371-067
1014372-067
1
1
Support, Heel Pocket, LH, Black
Support, Heel Pocket, RH, Black
14 7547069 8 Nutsert
15 5412067 4 Bumper, Rubber
16 5431501 1 Strap, Hood Latch
17 1013941 1 Latch, Seat
18 7621403 1 Rivet
19 5211033 1 Bracket, Lever Retainer
20 7041607 1 Spring, Latch, Light
7/04
A5
FRONT CAB and SIDE PANELS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
9
9
9
8
8
7
7
1
2
3
4
5
6
11
13
14
15
16
17
19
7
7
5
1
18
10
2
12
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 5434430-070
5434431-070
1
1
Panel, Side, LH, Black
Panel, Side, RH, Black
2 7518196 8 Screw
3 5434434-070
5434434-177
1
1
Cover, Front, Black (AA)
Cover, Front, Black Metallic (AB)
4 5246919
5246920
1
1
Bracket, Cab Mount, Front, LH
Bracket, Cab Mount, Front, RH
5 7542153 4 Nut, Nylok, Flange
6 2633008-293
2633008-496
1
1
Asm., Cab, Front, Indy Red. (AA)
Asm., Cab, Front, Comic Sun. (AB)
7 7512297 5 Screw
8 7552604 2 Washer
9 7547069 3 Nutsert
10 7670154 1 Retainer, Bolt
11 1014575-385 1 Support, Cab, Front, Silver
12 7552604 1 Washer
13 5434906 2 Pad, Front Cab Slider
14 7517455 2 Screw
15 5412334 6 Cap, Rubber
16 7512076 4 Screw
17 7571602 4 Washer
18 7555799 4 Washer
19 7547247 8 U-Nut, Chimney
7/04
A6
HEADLAMPS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
2
3
8
5
7
6
4
1
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 4010894 2 Bulb
2 2410303
2410304
1
1
Asm., Headlight, LH (Incl. 1)
Asm., Headlight, RH (Incl. 1)
3 5246589
5246590
1
1
Bracket, Headlight, LH
Bracket, Headlight, RH
4 7571602 4 Washer, Lock
5 7512076 4 Screw
6 7517910 4 Screw
7 7512084 2 Screw
8 5246591
5246592
1
1
Bracket, Headlight Adjuster, LH
Bracket, Headlight Adjuster, RH
7/04
A7
DECALS (AA)
PREDATOR A05GJ50AA
21
18
19
17
10
1
4
7
20
13
5
12
8
9
4
11
1
22
3
6
13
2
14
16
15
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7170621
7170622
1
1
Decal, Reflector, Red, LH
Decal, Reflector, Red, RH
2 7172855
7172856
1
1
Decal, Fender, Outside, Rear, LH
Decal, Fender, Outside, Rear, RH
3 7172853
7172854
1
1
Decal, Fender, Inside, Rear , LH
Decal, Fender, Inside, Rear , RH
4 7170896 3 Decal, “POLARIS”, Front/Rear
5 7170623
7170624
1
1
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
6 7172851
7172852
1
1
Decal, Fender, Front, LH
Decal, Fender, Front, RH
7 7172843
7172844
1
1
Decal, “PREDATOR”, LH
Decal, “PREDATOR”, RH
8 7172847
7172848
1
1
Decal, Front Cab, LH
Decal, Front Cab, RH
9 7172849
7172850
1
1
Decal, Cover, Front, LH
Decal, Cover, Front, RH
10 7078465 1 Logo, Polaris Star
11 7171030 1 Decal, “PRO STEERING”
12 7170982 1 Decal, “FOX RACING SHOX”, Swing Arm
13 7172669 1 Decal, Discretion Warning
14 7173013 1 Urocal, 50th Anniversary
15 7173297 1 Decal, Reverse
16 7172845
7172846
1
1
Decal, Tank Side, LH
Decal, Tank Side, RH
17 7172559 1 Decal, Age Warning, 16, ATV
18 7079902 1 Decal, 4 Stroke, Carburetor/Filter Information
19 7172566 1 Decal, Passenger Warning
20 7172668 1 Decal, Tire Pressure
21 7172560 1 Decal, Warning, General, CPSC
22 7171545 1 Decal, “Chain Freeplay”
8/04
A8
DECALS (AB)
PREDATOR A05GJ50AB
4
4
5
7
8 10
17
13
11
14
15
1
2
2
20
21
22
24
27
26
3
3
3
12
3
9
6
23
7
25
28
16
18
19
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7170982 1 Decal, “FOX RACING SHOX”, Swing Arm
2 7172669 1 Decal, Discretion Warning
3 7172745 8 Decal, “PREDATOR”, Rim
4 7170621
7170622
1
1
Decal, Reflector, Red, LH
Decal, Reflector, Red, RH
5 7172725
7172726
1
1
Decal, Rear Fender, Outside, LH
Decal, Rear Fender, Outside, RH
6 7172723
7172724
1
1
Decal, Rear Fender, Inside, LH
Decal, Rear Fender, Inside, RH
7 7171761 1 Decal, “POLARIS”, Front
8 7170623
7170624
1
1
Decal, Reflector, Amber, LH
Decal, Reflector, Amber, RH
9 7172741
7172742
1
1
Decal, Tank Side, LH
Decal, Tank Side, RH
10 7172739
7172740
1
1
Decal, “PREDATOR”, LH
Decal, “PREDATOR”, RH
11 7172733
7172734
1
1
Decal, Front Cab, LH
Decal, Front Cab, RH
12 7172735 1 Decal, Front Cover, “TLD”
13 7172736
7172737
1
1
Decal, Cover, Front, Stripes, LH
Decal, Cover, Front, Stripes, RH
14 7078465 1 Logo, Polaris Star
15 7172042 1 Decal, “PRO STEERING”
16 7172738 1 Decal, Emblem Stripes
17 7172721
7172722
1
1
Decal, Fender, Front, LH
Decal, Fender, Front, RH
18 5435424 1 Badge, 50 Years
19 7173297 1 Decal, Reverse
20 7172559 1 Decal, Age Warning, 16, ATV
21 7079902 1 Decal, 4 Stroke, Carburetor/Filter Information
22 7172566 1 Decal, Passenger Warning
23 7172727
7172728
1
1
Decal, Fender, Inside, Bottom, Rear, LH
Decal, Fender, Inside, Bottom, Rear, RH
24 7172668 1 Decal, Tire Pressure
25 7172729
7172730
1
1
Decal, Fender, Outside, Bottom, Rear, LH
Decal, Fender, Outside, Bottom, Rear, RH
26 7172560 1 Decal, Warning, General, CPSC
27 7171545 1 Decal, “Chain Freeplay”
28 7172731
7172732
1
1
Decal, Front Cab, “POLARIS”, LH
Decal, Front Cab, “POLARIS”, RH
7/04
A9
CONTROLS
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
22
3
21
1
2
4
5
6
8
7
20
9
11
19
12
14
13
15
16
17
10
18
10
23
24
25
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
1 7080922 1 Nut, Choke
2 7081221
7081097
1
1
Cable, Choke (If built before 10/04/04)
Cable, Choke (If built after 10/04/04)
3 5435785-070 1 Panel, Instrument
4 -------
-------
1
2
Holder (See Clutch Lever Pg. A10, Ref. 7)
Bolt (See Clutch Lever Pg. A10, Ref. 8)
5 4010594 1 Switch, Handlebar
6 5434628-070 2 Grip, Handlebar
7 7517625 1 Screw, Set
8 5432952 1 Plug, Hole
9 ------- 1 Asm., Clutch Lever
(See Clutch Lever Pg. A10 for Details)
10 7080138 5 Cable Tie
11 7081034 1 Cable, Clutch
12 ------- 1 Asm., Master Cylinder (See Front Brake
Master Cylinder Pg. B12 for Details)
13 2010191 1 Asm., Throttle Clamp
14 -------
-------
1
2
Clamp (See Front Brake Master Cylin-
der Pg. B12, Ref. 6)
Screw (See Front Brake Master Cylinder
Pg. B12, Ref. 6)
15 2010204 1 Asm., Throttle Control
16 5411439 1 O-Ring
17 5434113 1 Cover, Throttle Control
18 5410193 1 O-Ring
19 7081170 1 Cable, Throttle
20 5246383 1 Bracket, Instrument Panel
21 7518176 2 Screw
22 4010728
4010729
4011112
1
1
1
Indicator, Hot Light
Indicator, Neutral Light
Indicator, Reverse
23 2010248 1 Lever, Reverse Lock Out
24 5435971 1 Bezel, Reverse Lever
25 7517756 3 Screw
7/04
A10
CLUTCH LEVER
PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB
1
2
7
4
3
6
9
8
5
Part numbers may change after the making of the microfiche or paper copies. Electronic records are the most current.
Ref. Part No. Qty. Description Ref. Part No. Qty. Description
2010212 1 Asm., Clutch Lever
1 2010229 1 Lever, Clutch
2 2010228 1 Holder, Clutch Lever
3 2010227 1 Nut, Clutch Adjuster Jam
4 2010226 1 Adjuster, Clutch Cable
5 2410321 1 Switch, Clutch Lever
6 7518212 1 Bolt, Clutch Pivot
7 2010225 1 Holder, Clutch Lever, Lower
8 7518211 1 Bolt, Clutch Holder
9 7547253 1 Nut, Clutch Pivot
7/02
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- 2005 Polaris Predator 500 Parts Manual for Models PREDATOR 500 A05GJ50AA and PREDATOR 500 TROY LEE A05GJ50AB.
- ATVs are the ideal machine for maintenance and repair at home due to their reliable design, relatively simple construction, and ease of repair.
- With proper care and routine maintenance, your ATV will provide many years of reliable use.
- Most home mechanics will find ATVs easy to work with and repairs quick and trouble-free.
- Scheduled ATV maintenance should occur frequently at regular intervals, including changing the oil, inspecting various systems, changing spark plugs, and replacing filters.
- Holding a quality parts manual specific to your ATV will help you identify its parts and assist you during routine maintenance and repair.
- Doing routine maintenance at home is less expensive, prolongs the life of your ATV, and provides a better understanding of its working components.
- Even with diligent routine maintenance, ATVs may require periodic repairs, which can be made easier with access to service manuals and parts catalogues.
- Having a maintenance manual for routine maintenance and a parts catalogue for repairs will make ATV engine repair easier.
- Routine maintenance and periodic repairs at home will save you money and prolong the life of your ATV engine.
- 52 pages in English format that enables you to print only what you need.
- Contents include the following topics with exploded diagrams and part number lists: SPECIFICATIONS, FRONT CAB, REAR CAB and SEAT, REAR RACK MOUNTING, DECALS, FRONT RACK and BUMPER MOUNTING, ENGINE MOUNTING, COOLING SYSTEM, EXHAUST SYSTEM, FUEL TANK, OIL TANK, AIR BOX, FRONT DRIVE, FRONT TIGHTENER, FRONT STRUT, CV JOINT BTB, FRONT WHEEL, FRONT BRAKE, CONTROLS -- THROTTLE ASM./CABLE, CONTROLS MASTER, CYLINDER/BRAKE LINE, STEERING POST, HANDLEBAR and HEADLIGHT POD, A--ARM/STRUT MOUNTING, CENTER TIGHTENER, SWING ARM/SHOCK MOUNTING, DRIVE CLUTCH, DRIVEN CLUTCH, CLUTCH COVER, GEARCASE/BRAKE and CHAIN COVER MOUNTING, REAR BRAKE, REAR WHEEL DRIVE, ELECTRICAL/TAILLIGHT, GEARCASE, GEAR SELECTOR, PISTON and CRANKSHAFT, CRANKCASE and CYLINDER, RECOIL STARTER, CARBURETOR, OIL PUMP, MAGNETO, STARTING, MOTOR, TOOL KIT, PART NUMBER INDEX.
